Crane 11 RCA

Session One - 12 September 2022

Present

P Gowero M Bhunu T Jakarasi

T Panganayi S Makopa P Munanga
T Chidziya J Makoni S Marume (Chairman)
K Chivasa F Runoza L Moyo
L Mahuni M Chiramba (Host) O Mutizwa (Minute taker)

Background

Crane 11 experienced a series of breakdowns in the past weeks. Some of the notable ones
are the damage to the pantographs and hot rail insulators on the Red and yellow phases.
This resulted in a significant drop of Crane 11’s availability. Analysis of the events which took
place uncovered several issues which are possibly leading to Crane 11 breakdowns.

Crane 11 is situated at East plant in the Casting bay, and operates between Crane 2 and
Crane 13. Only Crane 11 is experiencing such problems. The issues of Crane 11 can occur
anytime during its operation.

Questions raised

The following questions were raised in trying to have a better understanding of the problem.
Answers for some the questions were put forward, some were answered during the site visit.

Why on Crane 11 only?

Crane 11 passes centre section more frequently than other cranes. It is also skewed
and seems to have a larger span.

Why on single phase?

The phase had a narrower shoe size compared to other phases. Hot rails are worn
out on the yellow phase where centre section meets Fce 6 side.

What prompts the replacement of hot rails?

Currently Hot rails are replaced upon failure.

Is there a drawing for the pantographs?

Yes, there is a drawing.

There was an issue with the arm length of the pantographs. Was it resolved?

Yes, it was resolved. There is a standard size for pantographs is currently in use.

Does it happen when Crane is coming from one direction only?

This can occur when crane is travelling from either direction but more prominent
when it is travelling from East to West.

Do we have a PPM to inspect the insulators for Crane rails?

We currently do not have a PPM for crane rail insulators, they are replaced upon
failure.

Are the hot rails aligned?

Hot rails are uneven especially on the Yellow phase which causes the shoe to be
lifted when Crane is passing by the centre section.

Observations on site

 No bolts on Crane bogey

 Crane gantry vibrates excessively when Crane 11 is passing near the centre section
 Girder prevents the Crane gantry from moving
 Gap between hot rails is too much (Fce 6 to centre section)

 Hot rails worn out at the centre section

 Swarf/chips observed on Crane rails
  Yellow phase shoe lifted up when Crane 11 was passing through the centre section
 Crane wheel wearing out induction furnace side

 Crane 11 skewed leaving a gap of approximately 100mm when put aside of Crane 2

SESSION TWO – 21 September 2022

Analysis
MANPOWER METHOD MEASUREMENT

MACHINE MEDIUM MATERIALS

Most likely cause based on fishbone

Use 5WHY PROCESS to find the root cause. Make sure you have evidence to back your
answers. DO NOT Guess.
Cause of Event 1 Cause of Event 2 Cause of Event 3

WHY?

2 WHY?

3WHY?

4WHY?

5WHY?

MOST LIKELY CAUSE OF FAILURE:

Action Plans

STEP #4 IMPROVE- SOLUTIONS/ SUGGESTIONS/ ACTION PLANS

What was done to resolve the problem?

What can be done to prevent the problem from happening again?

Work
Action to correct the situation Order By Whom By When Status

1
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