Are Your Crane Operations Stuck in the Past?

About a decade ago, the world recognized a new Industrial Revolution. It was the fourth of its kind since the very first Industrial Revolution in the 18th century, which introduced mechanized manufacturing processes. Today, Industry 4.0 is equally critical to businesses as machine power was to manufacturers long ago. The new shift is dramatically improving our ability to make products and get them into the hands of customers.

Industry 4.0 is all about the digital transformation of manufacturing and production processes. It leverages technologies such as automation, artificial intelligence (AI), Internet of Things (IoT) and the Industrial Internet of Things (IIoT), cloud and edge computing, and big data. With those technologies, manufacturers can create “smart” factories and warehouses, where equipment and systems are connected and communicating. Industry 4.0 is enabling levels of customization and automation - as well as efficiency and productivity - that weren’t even possible before.

Experts across the world are in agreement that those who aren’t able to adopt the new technologies risk being left behind. Industry consultants Deloitte say that “it would be folly to underestimate the crucial role the flow of information plays in the physical aspects of advanced manufacturing.”

The global pandemic has only fast-tracked the push to digital transformation for many manufacturers. A report by McKinsey showed that Industry 4.0 helped 94 percent of respondents to keep operations running during the crisis, and 56 percent said these technologies had been critical to their crisis responses. Unfortunately, the “companies that had not implemented Industry 4.0 prior to COVID-19 have had a wake-up call. … Not only did they find themselves struggling during COVID-19, but also the absence of past experience, lagging underlying IT/ OT technology stacks, and COVID-19-driven cash constraints are making it difficult for them to catch up.”

Companies that embrace Industry 4.0 technologies - such as networked systems, IoT, cloud technology, data analytics, human-machine interaction, and AI - set themselves up for great rewards. A McKinsey article stated: “The benefits these companies have recorded include 30 to 50 percent reductions of machine downtime, 15 to 30 percent improvements in labor productivity, 10 to 30 percent increases in throughput, and 10 to 20 percent decreases in the cost of quality.”

These benefits have a significant impact across the entire value chain and provide operational gains that are difficult to measure but equally important - better flexibility to meet customer demand, faster time to market, and improved integration within the supply chain.

Transform crane operations—and your bottom line

One area where Industry 4.0 technologies can be put to much-needed use is in crane operations in material handling environments. Whether you’re running gantry cranes, suspension cranes, bridge girder cranes, or rotary cranes, today’s advanced solutions can help you improve and optimize performance and efficiency, streamline processes, lower operating costs, reduce equipment wear and tear, keep teams productive, and more.
By connecting all of your cranes and other machines and applications into a single smart system, you’re able to increase business agility. Material handling organizations that fully embrace Industry 4.0 and put its technologies to use in their crane operations can develop new capabilities. They can also gather and analyze data from a range of sources to gain valuable insights into processes - which lead to more informed decision making and improved outcomes.

Cranes have been used in material handling for many decades. For many warehouses, factories, and mills, they are working essentially the same way they have since the beginning. Some organizations have updated their cranes to use digital technology, such as variable frequency drives and automation features. Today’s cranes offer an array of advanced features, including:

• Anti-sway control - Keep loads from swinging when crane speeds change during load handling. This helps reduce take time and keeps operation smooth.
• Shortest time start-up feature - Crane speed adapts automatically to changes in load mass. For instance, when a load is light, the crane will speed up.
• Tension control - Torque is controlled automatically for smooth acceleration and deceleration, ensuring the material tension stays consistent.
• Dedicated brake sequencing system - Shortens the time from startup to brake opening and improves response at low speed.
• Falling load detection - Detects unexpected load dropping. When the commanded direction differs from the actual motor rotation direction, the falling detection signal is output.
• Overload detection - Detects when a load is too heavy for the crane and will halt operation and alert the operator.

Watch Mitsubishi Electric’s ASRS solution in action

All of these features can certainly help improve operations - but another, more transformative step lies beyond that, which could be revolutionary for the organization.

One important benefit in using Industry 4.0 technologies in your crane operations is predictive maintenance. When cranes and other machinery are connected to back-office systems and AI applications, you get full visibility into each link in the value chain. As cranes begin to wear, smart systems can alert you to potential issues before they escalate and cause unexpected downtime or a safety incident.

With Industry 4.0 technology and the push for digital transformation, Mitsubishi Electric Automation designs provide products and solutions to enhance and increase productivity no matter the specific application. By incorporating smart controllers and inverters into conveyors and palletizers, and anti-sway technology for cranes and hoists, Mitsubishi Electric’s full portfolio of products decrease energy use while improving efficiency and safety. Refine your warehouse or distribution process by updating your controls, robotics, motors, industrial PCs, and drives with modern smart technology.

Visit our website to read more and watch a video about the solutions that solve our customers’ toughest challenges.