Safety takes a concentrated effort. It doesn’t just happen by chance; it is a series of good decisions, habits and carefulness combined with skills and knowledge that will help an operator return home at the end of the day. However, as the days turn into weeks and the weeks turn into months and then years, it is easy to become complacent with some of the less exciting facets of an operator’s job duties; such as the pre-shift inspection.
Maybe the operator just performed the pre-shift inspection yesterday, the day before that, and every day last week. Eventually they might not be taking it seriously. But, they NEED to take it seriously! We’ve seen very serious deficiencies that have existed for months sometimes years that would have easily been detected with a proper pre-shift inspection and follow up with the appropriate party.
The Requirements
So, how in depth is a pre-shift inspection and is there a documentation requirement? According to U.S. Federal OSHA there is no requirement for frequent or shift (daily) inspection to be documented. However, there is a requirement for monthly and annual inspections to be documented (see OSHA 1926.1412). Many companies do have a shift inspection checklist for their operators because it’s the best way to ensure that the inspections are being performed.
In the case of an overhead or bridge crane, most are operated from the ground using pendant control or wireless remote control. This means that access to the bridge and elevated areas is intended for those performing maintenance using an aerial lift or safe ladder procedures. This IS NOT an operator’s job. The operator performs the pre-use inspection by first observing for any obvious deficiencies, hazards and concerns. Then the operator runs the crane through each of the functions to ensure it is operating normally.
In the case of a mobile crane, the operator performs a walk around inspection looking at the various components while observing for any apparent deficiencies. Taking apart equipment components and booming down is not required as part of the inspection unless the results of the visual inspection or trial operation indicate that further investigation is necessary. And, while we are at it, what about the trial operation? This is when the operator runs the crane through all operational modes to ensure the crane is operating normally. In other words… if the crane isn’t going to operate as expected let’s find out before we start making a lift.
Who Inspects?
Now, instead of listing a long and comprehensive list of all the items that make up a pre-shift inspection, let’s consider who performs the inspection. That’s easy right? It is the operator, right? Wrong! It is the Competent Person. Operator… Competent Person… one in the same? Maybe and in most cases it is the operator, but there are cranes and crews where the Competent Person inspecting the crane is not the operator.
When the crane operator performs the pre-shift inspection the operator takes on a new role of Competent Person. This means the operator (pre-shift inspector) must be capable of recognizing maladjustments, excessive wear, deteriorating hydraulic and electrical lines and connections. The pre-shift inspector must be able to look at the hook and latches to ensure they are safe to use and, in some cases, the right type for the job. Then there are the tires on a mobile crane that must have sufficient air pressure. Have you ever considered that by having an operator inflate/deflate the tires that he or she may actually be performing ‘service’ on a split rim wheel? This is some serious stuff, which is why Crane Tech recognizes the special knowledge and skills required to perform pre-shift inspections.
What’s the Focus?
Let’s look at the pre-shift inspection in another light. It is easy to argue that a pre-shift inspection is intended to create a safe environment. Who would not agree that safety is a paramount reason for these inspections? But, consider the pre-shift from another perspective. What if it is also intended to keep the job running and the folks on the ground working and being productive? Many times small problems found during pre-shift inspections can be resolved quickly and for less cost which also keeps downtime to a minimum. Small problems that are not found turn into bigger problems and bigger problems bring longer repair times, higher repair costs and more downtime. There is an old rule that says ‘nothing ever breaks when it isn’t being used.’ Your car, your lawn mower, your heating and air conditioning system in your home, and certainly your cranes.
When operators lack training on what to look for during the visual inspection they put the entire job at risk not only for safety but for production. Being competent to perform an inspection doesn’t come from association, but rather from training. What is that noise my overhead crane is making? When I swing my mobile crane it doesn’t stop like it used to. Are we lifting a personnel platform with the crane and is the hook safety latch the correct type? Why is the hydraulic motor making a whining noise? Why does the load continue to drift down after I release the lower button on the pendant? And on and on and on…
What Do You Do With It?
We believe that recording the pre-shift inspection is not only the proper thing to do, but the right thing to do. It can be the first line of defense in the event that something goes wrong. However, we often find the checklist stays at the crane, or has no intended path to someone in maintenance or other authority. If you wonder why your operators don’t seem too interested in filling out a checklist you should first look at how the checklists are treated. It has been known that if no one comes around to verify that pre-shift inspections are being properly carried out and if no one collects these documents, then the feeling could be that management does not care about them.
So we challenge you to stop, and take a long look at your pre-shift inspection process: who is doing the inspection, what are their skills and experience, and where do the findings go? Having these reports land on the maintenance manager’s desk each day and turning them into a list of action items by fixing the minor concerns before they become major items, goes a long way to telling an operator that you are engaged and interested in their findings. Let the first line of defense give you a fighting offense so your site can remain productive and safe.