Case Study

10-zone overhead crane system released to production a month ahead of contract.

Industry: Aerospace, Transportation

When a Tier-1 aerospace prime broke ground on a new U.S. facility for high-value rotating jet-engine components, the project team needed an overhead crane and hoist partner who could move at the pace of a brand-new plant ramping toward production. The site was ITAR-controlled. The parts being lifted were small in footprint but extraordinary in value. And every workstream (engineering, factory fabrication, on-site installation, operator training, and commissioning) had to converge on a contractually fixed year-end go-live with no margin for slippage. Han-Tek delivered the full Phase 1 turnkey scope and released the cranes to production a full month ahead of the December 31, 2010 commissioning deadline.

Their Challenge:

Equip 10 production zones (manufacturing zones, three Coordinate Measuring Machine zones, plus dedicated calibration, maintenance, and stores areas) inside a brand-new aerospace plant with bridge cranes, hoists, runway systems, and controls engineered to CMAA Class “C” precision standards for repetitive high-value lifts.
Hit a contractually fixed commissioning completion date of December 31, 2010, with roughly an 8-week on-site installation window once fabrication wrapped.
Operate inside an ITAR-controlled aerospace environment, where supplier compliance, data handling, and traceability requirements add layers most general overhead crane integrators are not built for.
Protect personnel and high-dollar rotating parts during operation by preventing bridge collisions across multiple shared runway systems.
Coordinate engineering, procurement, factory fabrication, on-site installation, training, and final documentation against a single year-end milestone, inside a plant still being commissioned around the work.

Our Solution:

Han-Tek delivered a turnkey crane and hoist system, spanning 10 production zones (Zones 1, 2, A, and B, plus three CMM zones C1-C3 and dedicated bridges serving calibration, maintenance, and stores). Han-Tek built the single-girder bridges in-house and paired them with R&M 2-ton electric chain hoists.
Bridge systems were engineered to CMAA Class “C” indoor service. VFD bridge control delivered smooth, precision-grade motion (120 fpm bridge max, 80/20 fpm two-speed trolley, 16 fpm hoist) on 460V / 3-phase / 60Hz industrial power.
A Telemotive laser-based anti-collision system was specified and installed on every bridge to safeguard personnel and the high-value parts being moved across shared runways.
A dedicated Han-Tek project manager held single-point accountability across every workstream: engineering, procurement, fabrication, installation, OSHA-required 125% load testing, operator training, and turnover documentation.
A critical-spares package was stocked on-site at PO award, hardening the schedule against any equipment-side surprises during an 8-week install running against a hard year-end commissioning deadline.

The Results:

Released to production a month ahead of contract: Phase 1 crane systems were released for production on November 29, 2010, 32 days ahead of the December 31, 2010 contractual commissioning date. Final documentation was delivered December 3, 2010.
8-week on-site install completed without disruption to plant ramp: From mobilization through 125% load testing and operator training, every workstream landed on the published schedule.
Earned follow-on phases: Phase 1 execution opened the door to additional crane scope at the same facility in subsequent years.
Reliable in service: The Phase 1 crane and runway systems remain in continuous service in a precision aerospace production environment.

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