Cranes, Hoists, & Rigging

Policy Key Points

• Only qualified and certified individuals are authorized to operate cranes, hoists, and rigging equipment across Yaskawa facilities.
• Mandatory Daily Shifts Inspections: Daily-use and occasional-use cranes must undergo functional and visual checks prior to shift operation; out-of-service cranes require engineering inspection before return.
• Lift Safety Rules: Never move loads over personnel, avoid side pulls and shock loading, and obey Emergency Stop signals immediately regardless of who gives them.
• Rigging Standards: Wire rope slings require a 5:1 safety factor; "job-made" rigging is strictly prohibited; damaged rigging must be immediately destroyed.
• Tiered Qualifications: Structured operator certifications cover Awareness, ≤5 Ton, 5–10 Ton (Specific/General Use), and >10 Ton VFD cranes (Specific/General Use).

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Policy

Overview

Responsibilities

Cost Center Managers

Cost Center Managers of departments in which crane and hoist equipment is located are responsible for:

• Performing (or coordinating) annual maintenance and inspection of all cranes and hoists within their cost center. Conducting or coordinating special load tests of cranes and hoists.
• Maintaining written records of inspections and tests.
• Inspecting and load testing cranes and hoists following modification or extensive repairs (e.g., a replaced cable or hook, or structural modification).
• Scheduling a non-destructive test and inspection for crane and hoist hooks at the time of the annual load test, and testing and inspecting before use new replacement hooks and other hooks suspected of having been overloaded (including visual, dye penetrant, and magnetic particle techniques referenced in ASME B30.10).
• Maintaining all manuals for cranes and hoists in a central file for reference.

Supervisors

Supervisors are responsible for:

• Ensuring associates under their supervision receive the required training and are certified to operate the cranes and hoists in their areas of responsibility.
• Providing training for prospective crane and hoist operators.
• Evaluating crane and hoist trainees.
• Ensuring that hoisting equipment (crane, hoist, rigging) is inspected and tested daily (or prior to each use for hoisting equipment that is not used daily) by a responsible individual.

Crane Operators

Crane and Hoist operators are responsible for:

• Operating hoisting equipment safely.
• Conducting functional tests prior to using the equipment.
• Selecting and using rigging equipment appropriately.

General Crane Safety Rules

Operators shall comply with the following rules while operating cranes and hoists:

• Do not engage in any practice that will divert your attention while operating the crane.
• Respond to signals only from the person who is directing the lift, or any appointed signal person.
  • An Emergency Stop signal must be obeyed immediately regardless of who gives it. Standard "Stop" signals are typically directed by the assigned signal personnel.
• Do not move a load over people.
  • People shall not be placed in jeopardy by being under a suspended load.
  • Do not work under a suspended load unless the load is supported by blocks, jacks, or a solid footing that will safely support the entire weight. Have a crane or hoist operator remain at the controls or lock open and tag the main electrical disconnect switch.
• Ensure that the rated load capacity of a crane's bridge, individual hoist, or any sling or fitting is not exceeded. Know the weight of the object being lifted.
• Check that all controls are in the OFF position before closing the main-line disconnect switch.
• If spring-loaded reels are provided to lift pendants clear off the work area, ease the pendant up into the stop to prevent damaging the wire.
• Avoid side pulls. These can cause the hoist rope to slip out of the drum groove, damaging the rope or destabilizing the crane or hoist. The load should always be directly below the hoist.
• To prevent shock loading, avoid sudden stops or starts. Shock loading can occur when a suspended load is accelerated or decelerated, and can overload the crane or hoist. When completing an upward or downward motion, ease the load slowly to a stop.

Crane, Hoist, and Rigging Inspection

All tests and inspections shall be conducted in accordance with the manufacturers recommendations.

Daily Inspections

All cranes shall be inspected on each shift in which they are used prior to operating the crane on that shift.

There are three categories of cranes for the purpose of this inspection requirement:

• Daily Use Cranes: Frequently used cranes inspected on each shift of use.
• Occasional Use Cranes: Inspected only on shifts when used; no inspection required on unused days. Once passed, valid for remainder of shift.
• Out-of-Service Cranes: Removed from service and locked out. Must be inspected by Manufacturing Engineering or competent authority before returning to service.

The daily/shift test shall include, as applicable:

• Test upper-limit switch slowly with unloaded hook block.
• Visually inspect hook, load lines, trolley, and bridge from the ground.
• Test lower-limit switch (if provided).
• Test direction and speed controls for bridge and trolley.
• Test bridge and trolley limit switches (where provided).
• Test pendant emergency stop.
• Test hoist brake to verify no drift without a load.
• Inspect hook for damage and check safety latch.
• Inspect slings for wear.

Annual Inspections

Cost center managers shall coordinate annual inspections with an authorized inspector covering: hoisting/lowering mechanisms, trolley/bridge travel, limit switches, structural members, bolts/rivets, sheaves/drums, pins, bearings, brake systems, indicators, sprockets, hooks, electrical apparatus, wire rope, chains, and rails.

Load Testing

Load testing shall only be performed by an authorized contractor or Professional Mechanical Engineer:

• Newly installed cranes/hoists: Load tested to no greater than 125% rated capacity.
• Slings: Must have certified test data upon purchase maintained by Cost Center Manager.
• Re-rated cranes/hoists: Tested to no greater than 125% of new capacity.
• Modified/repaired fixed cranes: Tested to no more than 120% rated capacity.
• Overloaded cranes: Must be inspected prior to return to service.
• Personnel platforms/baskets: Load tested initially and re-tested annually.

Operator Qualifications

All workers operating Yaskawa cranes shall complete crane safety education and hands-on training with a qualified trainer, updating their competency record upon completion.

Levels of Qualification

Overhead Crane Safety Awareness Training: Provided to all associates working in areas where overhead cranes operate.

Overhead Crane Qualified ≤ 5 Ton: Required for operating production and warehouse cranes ≤ 5 tons.

Overhead Crane Qualified 5 Ton to 10 Ton: For VFD-controlled cranes (e.g., CT cleanroom, laboratories). Features two certification types:

• Specific Use: Qualified for specific lifts only (e.g., CT plate).
• General Use: Competent for critical lift plans and any load within rated capacity.

Overhead Crane Qualified > 10 Ton: Required for cranes > 10 tons (e.g., Franklin bridge crane). Features Specific Use and General Use certifications.

Design Requirements

• Cranes and hoists must comply with ASME/ANSI B30 and CMAA specifications (CMAA-70 and CMAA-74).
• All hooks must have safety latches; hooks shall not be repainted if factory paint wears off.
• Pendants must feature an electrical disconnect switch/button.
• Cranes/hoists require a lockable main electrical disconnect switch.
• Bridge, monorails, and hook blocks must be clearly labeled with maximum rated capacities on both sides.

Crane & Hoist Operation

Personal Protective Equipment

1. Hard Hats: Type 2 Class A hard hat must be worn:
   • Franklin FR1 Facility: Whenever operating an overhead crane or within the load fall zone.
   • All other Facilities: Whenever operating an overhead crane with load above chest level.
2. Safety glasses with side shields.
3. Safety shoes with toe protection.

Moving a Load

Center hook over load to prevent cable overlapping or load swinging. Verify cable is in drum grooves. Plan travel path, lift only high enough to clear obstructions, start/stop slowly, land safely, and never leave suspended loads unattended (barricade and tag out if inoperative).

Parking a Crane or Hoist

Remove slings/accessories, raise hook at least 7 feet above floor, store pendant clear of aisles (or ≥7 feet high), and press Emergency Stop to OFF.

Rigging

General Requirements

Inspect rigging equipment annually. Capacities must be stamped on components. Wire rope slings require a 5:1 safety factor. Defective equipment must be destroyed immediately.

Rigging Defects (Reject & Destroy)

Rigging the Load

1. Determine load weight accurately.
2. Select proper sling sizes; do not use manila rope.
3. Ensure shoulderless eyebolts are threaded at least 1.5x bolt diameter; prefer swivel safety hoist rings.
4. Pad sharp edges with wood or tire rubber.
5. Do not use welded, cut, or "job-made" rigging; use forged, certified hardware only.
6. Install wire-rope clips with base on live end and U-bolt on dead end.
7. Determine center of gravity and test lift a few inches to verify balance.

Standard Hand Signals

When the operator's view is obstructed, qualified signal personnel direct the move using standard signals. All Emergency Stop signals must be obeyed immediately, regardless of who gives them.

Records and Forms

Record Title	Retained by	Disposition
Daily Crane, Hoist, Sling Inspection	Cost Center Manager	Retain for 5 years (min)
Annual Crane, Hoist, Sling Inspection and Load Test	Cost Center Manager	Retain for 5 years (min)
Initial Crane/Hoist Certification (Includes move/modification)	Cost Center Manager	Retain for life of equipment
Crane Operator Qualification	Associate’s Supervisor	Retain for employment tenure plus 3 years (min)

Training

Awareness training is provided to all associates within 90 days of employment. Operators must complete qualification and hands-on training prior to operating equipment. Records are retained by supervisors.

External Resource Video: Lifting Safely: Cranes, Hoists, and Rigging

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Revision History

Rev #	Description	Release Date	Approved by
0	Conversion of old safety documents, rewrite, and issue	4/11/2016	Thurwanger
1	Added Standard Hand Signals	2/12/2019	—
2	Added Crane and Hoist Safety Design Requirements	2/8/2023	—
3	Added Crane Assembly and Disassembly	3/26/2025	—

Program Review

Review Date	Reviewed by	Changes Required (Yes/No)	Revision # if updated
2/15/2017	Thurwanger	No	—
1/10/2018	Thurwanger	No	—
1/17/2019	Thurwanger	Yes	1
1/9/2020	Thurwanger	No	—
1/19/2021	Thurwanger	No	—
1/13/2022	Thurwanger	No	—
1/26/2023	Thurwanger	Yes	2
1/11/2024	Thurwanger	No	—
1/16/2025	Thurwanger	Yes	3
2/11/2026	Thurwanger	No	—