Operator Training - Making a Difference

With the many technical advancements being incorporated in cranes, manufacturers and crane owners in conjunction with certifying agencies are adopting new training standards to bring greater efficiencies in the performance of their cranes. NBM Media takes a look.

Advanced training programs that include crane operation and maintenance are fast becoming a key sales differentiator amongst manufacturers as they bring new technologies in their equipment. Given the high initial costs incurred in procuring the more advanced, new-generation cranes, training operators in their use has attained critical importance in order to derive optimum performance and ensure safety of the machines.

Liebherr, which has recently made critical advancements in its medium and heavy crawler and mobile cranes, is enhancing its training standards for the operators. Says Subhajit Chandra, Divisional Head, Liebherr Cranes India, "All our crawler, rough terrain and All Terrain cranes are now based on the advanced European EN 13000 standards, in accordance with which, we are making operators fully acquainted with the new standards and the cranes' new functionalities. We give a refresher training program of 5-7 days once a crane has been commissioned at the site. Operators are also trained to undertake troubleshooting."

"To ensure minimal downtime of our cranes, we are in constant communication with the operator. In case of any fault detected by the operator, we simulate its cause on our systems, supported by our in-house software's error codes. A snag can be caused due to a fault in the fuse or the sensors, and we convey the repair solution to the operator over phone, but if he is unable to detect the problem, we send our service personnel to the site to carry out the necessary repairs and get the crane working," he adds.

Pradhan Mantri Kaushal Vikas Yojana (PMKVY) is the flagship scheme of the Ministry of Skill Development & Entrepreneurship (MSDE). The objective of this Skill Certification Scheme is to enable a large number of Indian youth to take up industry-relevant skill training that will help them in securing a better livelihood. Individuals with prior learning experience or skills are assessed and certified under Recognition of Prior Learning (RPL).

The Infrastructure Equipment Skill Council (IESC), promoted by the Indian Construction Equipment Manufacturers Association (iCEMA), supported by the Confederation of Indian Industry (CII) and National Skill Development Corporation (NSDC) is spearheading the skilling of workforce in the Infrastructure Equipment Sector with primary focus on training and certification of operators and mechanics.

SANY Heavy Industry India Pvt. Ltd., on account of high impulse towards organising trainings for the operators has become the ideal partner for this initiative on behalf of IESC and made strategic investment in State-of-the-art training facility for such training events,.

Deepak Garg, CEO - Sany South Asia, informs that the company has entered into a collaboration with the Crane Owners Association and with IESC (Infrastructure Equipment Skill Council) for developing a training program for operators.

"The program is both classroom-based with simulation and at site where complete hands-on training is provided. With cranes becoming more complex and high-tech, and with diverse onsite conditions and requirements, we have customized the training program to cover parameters like crane operation, Safety and machine Maintenance," informs Garg.

With experienced trainers and well prepared training content, these trainings are proving very beneficial for all operators. So far SANY has trained and certified over 150 operators in a span of one year.

TIL undertakes several crane training initiatives to optimize performance of its operators and thereby of its machines. Says Pinaki Niyogi, VP, CTO, TIL Ltd, "We offer classroom training for operators and we train them at job sites as well so that they get first-hand experience of the ground realities when operating a crane. The focus of our training module is also to make sure that the operators understand the safe and productive use of our mobile cranes."

Schwing Stetter India believes that sending its customers to its crane manufacturing facility in China is the best way to get them fully aware of the high quality standards of the product and to appreciate the highly automated manufacturing processes. Says, V.G. Sakthikumar, MD, Schwing Stetter India, "We provide both classroom and onsite training to operators working on our XCMG tower, mobile and crawler cranes. However, a visit to our manufacturing facility gives them a close understanding of the features and functionalities of the cranes, especially of the engines, booms and other critical parts, which enables them to carry out maintenance work in a better way."




Liebherr crawler crane division in India handling 110 t to 300 t capacities, emphasize a lot on training their service engineers at Liebherr Werk Nenzing, factory in Austria. We ensure that we impart training to our engineers on regular basis so that they are abreast with the latest innovations including software and hardware, says Ghananeel Molankar, (Divisional Head - Construction Machinery), Liebherr India Pvt. Ltd., "Most of our crane operating software's are indigenously developed. Training of our service engineers is of prime importance as it enables them to perform the right diagnosis and ensure safe operations on site. The cranes have advanced electronic control systems, integrated with sensors, and perform real-time load calculations for safe lifting operations. We provide onsite training as well as conduct customized class room trainings based on the different needs of the customer. Liebherr Werk Nenzing manufactures three different product groups - crawler cranes and foundation equipment. These products can be used for numerous applications and hence the application know-how also becomes important for our service team."

Nandedkar- GM Sales, Kobelco Cranes, informs that the company has an end-to-end comprehensive training program. "Our service team gives a basic two-day onsite training to supervisors and operators on following safety procedures while operating the cranes, once they have been commissioned. Our second level of training is to the maintenance personnel, following 5000 hours of operation of the cranes. Here we impart training on the procedures for inspection of the hooks, ropes, wire ropes loadcells anemometer etc, to ensure timely upkeep of the cranes 'Decade to Decade' is a Inspection, Where cranes which have completed life of 10 years, our service personnel carry out detailed inspection of the pressure hoses, boom joints, undercarriage, sprockets, electrical components, load moment indicators, and the diameters of the ropes. Following this, the customers are advised on replacement of the worn-out components. Training is also given to ensure higher availability of the cranes across its lifecycle."


He added, "Our main aim to improve the technical knowledge of customer and his team about crane operation, safety and maintenance. The customer who receives the necessary technical training about crane, can perform their job easily and efficiently. A training program improve strengthen those skills that each customer needs to improve. A training program brings all employees to a higher level so they all have similar skills and knowledge. Training is provided by us as per candidates qualification and designation (Operator or Technician).


On Kobelco's Training program Formats, he says, "Previously our Training program were conducted as per Kobelco schedule. Date, Place and Types of Training were fix as per training calendar but now we are conducting "Tailor made" training programs. Training will be conducting as per customer convenient time and place. We can arrange training program at customer site, their office or our Sricity factory as per their convenience. We are able to provide Training in Indian regional languages also. We provide two types of training: Basic Training Program for Operator & Trainee Engineer and Advance Training Program for Senior Engineer and Manager."


Infrastructure Equipment Skill Council (IESC)s 'Not for Profit' sustainable organization, promoted by Indian Construction Equipment Manufacturers Association (iCEMA) and funded by National Skill Development Corporation (NSDC) has developed Qualification Packs (QP's) and National Occupational Standards (NOS) with the involvement of Equipment Manufacturers, Customers & User Industry through their consultant LabourtNet Deloitte and approved by NSDC and National Skill Development Agency (NSDA) Govt of India, Ministry of Skill Development & Entrepreneurship covering 39 job roles for the equipments including Hydra, Truck Mounted & Crawler Cranes.

Says H S Mohan, Chief Executive Officer, Infrastructure Equipment Skill Council, "Curriculum for these equipments have also been developed for structured training. The Skill Set for Junior Crane Operators and Operators have been defined with their career growth plan. The standards define on the operational efficiency covering a) Pre-operational checks b) How to operate the crane c) Perform routine maintenance and troubleshooting d) Comply with worksite health and safety regulations."

IESC has over 55 affiliated training partners and IESC certified Trainers to conduct the training. The module for the training of Operators is 70% hands on and 30 % class room session. Manufactures like SANY, TIL, ESCORTS, ACE and Kobelco are partnering with IESC. Crane Owners Association of India (COAOI) have signed MOU with IESC to upskill their existing operators. These programs have been well received. All the successful candidates are awarded with Govt of India Certificate.

Satin Sachdeva, Founder & Secretary General, CERA and MD & CEO of Equipment Planet, avers, "We are taking a more organized approach in training the operators of our CERA members, in association with IESC, Skill India and our associated manufacturers. Operators are being trained well to prevent any safety lapses while using the construction equipments and cranes . It has been found that most accidents in India take place when junior crane operators or even helpers take on the job of the main operator on operator absence or due to negligence .So to prevent such lapses, we have widened our training module to train the junior operators and helpers as well."

No doubt, IESC and crane manufacturers are imparting the much-needed training in a concerted manner; however, training will have to be an ongoing exercise as cranes will continue to be upgraded with further technological advancements.

Lifting & Specialized Transport — January - March 2019