Cranes & Hoists

FW 2.0 - Sub Element 7.1

Imagination at work.
Revised in Jan. 2016
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Applicability
 All types of overhead and mobile cranes.
 Other fixed & temporary lifting equipment, such as winches, hoists,
chain blocks and lifting equipment & load attaching ancillaries.

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Transitioning from legacy FWs
Tier 2 only:
GE employee or GE supervised contractor uses fixed or mobile crane or hoists.

Out • Written Crane Safety Program. 7.1 Cranes and Hoists

7.1.1 HS13 13.4.2.1
7.1.2 HS13 13.4.2.2
7.1.3 HS13 13.4.3.1
7.1.4 HS13 13.4.4.1
Changed • Nothing. 7.1.5 HS13 13.4.3.2
7.1.6 HS13 13.4.4.1
7.1.7 HS13 13.4.3.2

New • Collection of inspection documentation for cranes and hoists prior

to using the equipment at the GE customer's location.**
• Organization ensures that a detailed and documented annual
thorough examination has been completed by the GE customer on
their owned or leased cranes, hoists, and rigging that is utilized by
our employees or contractors. **

** Distributed Workforce only

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Activities overview
Develop inventory of Cranes and Hoists

Assess Organization Process against GE Crane Manual

Develop and Implement Improvement Plan based on Assessment

Develop Lift Plans or Risk Assessments

Provide training based upon level of responsibility & job task classification

Develop inspection criteria and process for all cranes and hoists

Establish process to obtain customer doc. for required inspections (DWF)

Conduct annual program review in accordance to GE Crane Manual of
inspection records, confirmation of compliance

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 What we will be looking at (Process flow)
Equipment Inventory Review against GE Crane Manual Lift plans & Risk Assessments Train EEs & contractors

(1) Hoist & Crane Inventory (2) Assessment of Crane & Hoist Program (3) Lift Plans and Risk Assessments (4) Training & Communication
FW 2.0: No question Question 7.1.1 (Tier 2) Question 7.1.1 (Tier 2) Question 7.1.2 (Tier 2)
Guidance: Guidance: Guidance: Guidance:
• Develop inventory of hoists • Assess GE Crane Safety Manual against • Develop Crane and Hoist Lift • Provide awareness training to
and cranes. Organisation’s practices and program. Plans (critical lifts) or Risk all employees covered under
• Understand the lifts these • Based on the assessment, make Assessments (normal lifts). the Crane and Hoist program.
devices are used for. improvements so Organisation’s • Communicate the Crane and
program meets GE requirements. Hoist program to affected
contractors.
• Train all employees involved in
cranes and hoists according to
their responsibilities.

Inspections: pre-use, monthly, annual Use at Customer sites Program review

(5) Inspections for Cranes and Hoists (6) Inspections for Customer’s Cranes and Hoists (7) Program Review and Improvement
Questions 7.1.3, 7.1.4 & 7.1.5 (Tier 2) Question 7.1.6 (Tier 2) - DW only FW 2.0: No question
Guidance: Guidance: Guidance:
• Establish a process to conduct the required • Establish a process for GE to obtain the inspection • In accordance with the Crane Safety
pre-use, and monthly information from the owner of the crane/hoist. Manual, conduct an annual review of
• Establish a competent person or vendor to • Obtain the documentation of the most recent inspection records and confirmation
conduct an Annual Thorough Examination Annual Thorough Examination inspections. of compliance.
inspections. • Conduct a pre-use inspection.
• Conduct pre-lift meetings as needed.
• Issue lift permits as required.

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Inventory of Cranes and Hoists
• GE Crane Safety Manual –
“Each location must have a process in place to develop a documented
inventory of all Cranes/Hoist and Rigging/Attachments.”
o Updated regularly to include equipment name & type, location, serial
number, maintenance company, fit for service status, etc.
o Strong links with Management of Change & maintenance programs.

• Sourcing cranes & lifting equipment:

o Suitable for use – right tool for the job.
o Marked with the safe working load.
o CE marked (applicable to European sites).

• Material condition:
o Any material with a major defect/ malfunction or not controlled must be put
out of service and lock apply with tag “out of service” or equivalent.

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Inventory Good Practice
 Selmer Crane & Hoist Inventory
(from OneEHS Guidance materials)

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7.1 Cranes & Hoists
7.1.1 – ALL – Tier 2
Has the Organisation developed lift plans or Safety Risk Assessments for lifting
operations?

The Organisation shall evaluate all

crane and hoist operations in Multiple aspects:
accordance with the GE Crane Safety
Manual. Lift plans shall be developed • Review against GE Crane Safety Manual.
for critical, engineered, and new
product lifts. Safety Risk Assessments • Categorizing lifts: Risk Assessments & Lifting Plans.
shall be developed for normal lifts (not
critical, engineered, or new product). • May be completed by a lift permit based on local
A learning team approach and
regulations or local Risk Assessment.
questioning attitude should be used.

The Element 5 Risk Assessment SRA Lifting Plan

questions apply to all risk
Normal Lifts
Routine

assessments, except IH risk

assessments, regardless of where the
Critical Lifts
risk assessment requirement appears
in this Framework. Normal Lifts
Non routine

New/Modified Product Lifts

Critical Lifts

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Cranes & Hoists: categorizing lifts
Critical Lift
A lift that requires:
- The use of 75-100% of the rated capacity of a fixed or mobile crane, or
- The use of 2 or more cranes to perform the lift, or
- Involves lifting of loads (with a ratio of less than 1 ton per m2 exposed to the wind) that may sail in outdoor conditions, or
- Personnel lifts, or Complex lifts at the discretion of the Competent Person or Operator (example might include; Lifting
hazardous materials, Lifting materials that could create an environmental impact, lifting over critical equipment, etc.)

Engineered Lift
A lift that exceeds the rated capacity of the crane. Engineered Lifts require business level approval by a qualified person
before the lift can be executed. Other restrictions are detailed in GE Crane Manual & Engineered lifts that exceed the safe
working load of the crane are not permitted with mobile cranes.

New/Modified Product Lift

A lift that involves either a new or a modified product where the modification would impact either the SRA or Lifting Plan.

Normal Lift
A lift that is does not meet the requirements of being a Critical, Engineered or New Product Lift.

Routine Lift
These are lifts that are carried out on a regular basis and/or integral to the production process that require no detailed
engineering planning and which have been previously subject to a generic or specific SRA or Lift Plan.

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Lifting Operations Identify Need for Lifting Operation

flowchart Appoint Competent Person to plan, with

Technical Authority as Needed

Routine Lift Non-Routine Lift

Conduct Risk Assessment Conduct Risk Assessment

New/Modified Normal Critical

Normal Critical Engineered Normal Critical
Product

Business Level Lift Approval

Develop SRA or Lift Plan Develop Lift Plan Develop Lift Plan

Approved by CP or TA Developed & Approved Developed & Approved

by TA by TA

CP = Competent Person
TA = Technical Authority
Appoint Team Appropriate for
SRA = Safety Risk Assessment Lift
LP = Lift Plan

Non-Routine Lift: Toolbox Routine Lift & Lift Team

Talk, review Risk Assessment familiar with SRA or Lift
and SRA/Lift Plan with all Plan If Problem Detected, STOP in
Personnel Safe Position and Review
Risk Assessment and SRA or
Lift Plan
Perform Lift with Appropriate
Supervision

Post Job Debrief - note

learning points 11
Cranes & Hoists: Lift Plans & SRAs
• Crane & Hoist Risk Assessment Tool -

• Live Demo today -

Electronic Crane Lift Plan Tool

• GE Crane Safety Manual -

o Lift Plan template
o Example of Lifting SRA
o Example of Lift Permit

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Focus: Crane safety distance

A simple consistent method will help

drive safe behaviours…
BUT do consider loads lifted and
materials used when communicating!

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7.1 Cranes & Hoists
7.1.2 – ALL – Tier 2
Has the Organisation trained all GE employees, and GE supervised contractors, on the
specific requirements of the cranes or hoists that they operate?

In accordance with the Crane Safety • Licences or certifications as required by local regulations.
Manual, the Organisation shall assign
training requirements to Level 1
operators, Level 2 operators, team • Training courses & contents, practical evaluations & tests and
members, qualified, and competent refresher expectations are clearly defined in the crane manual.
person(s). Training shall be delivered
prior to initial operation of the
equipment. • Training for Qualified Persons include -
All operators shall be trained on the o Contractor: Location must verify training/certification &
specific requirements of the cranes work experience to confirm person(s) are qualified.
and hoists they operate as specified in
the Crane Safety Manual. Training o In-house: Training by a qualified 3rd party (ex. Crane
shall be included in the Organisation’s Companies, Engineering Organizations, Crane
training matrix.
Manufacturer, Labour or Government Agencies, etc.)
Gensuite Training Tracker tool may be o For in-house, locations can send persons to become a
used to help verify completion of this
requirement.
train-the-trainer.

This is a 1-deficiency question. • Location must identify qualified persons in their operations…

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Cranes & Hoists: key roles
Operations must develop a roster that outlines which personnel will be:
Competent Person(s)
Specifically identified person who is designated as having the required level of competency to plan and supervise the specific
lifting operation. The competent person should have the practical skills, theoretical knowledge and ability to carry out risk
assessments, produce and assess lift plans, conduct pre-lift meetings and have the supervisory skills and experience required
to manage a specific lifting operation.

Technical Authority
Someone who is technically competent and can make an informed and impartial judgment of a lifting operation plan or
installation procedure and provides a technical authority review. For example, this person is typically a structural or
mechanical engineer with specific knowledge on crane/lifting operations.

Operator(s)
Person who operates the controls of a crane/hoist and implements the requirements of a SRA or Lift Plan. This can be a GE
person or outside contractor.

Lift Team Member(s)

Personnel who assist the operator while carrying out lifting operation.

Based on qualifications, one person may fulfil multiple roles.

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Focus: Crane operators training
1st rule: Country-specific or local crane training regulations
and certifications for operators and trainers must be met.

• Level 1 Operators are competent to perform complex lifts (parts >10T, multiple crane lifts, etc.)
• Level 2 Operators are competent to perform less complex lifts (straight lifts, etc.)

• Training delivered to Crane Operators includes at minimum: GE Learning latest course codes
o Classroom or online instruction.
o Practical training (adjusted for level 1/ level 2). Work with or around overhead cranes and rigging:
• Online initial/refresher courses: GE-EHS-465/465R
o Effectiveness: written exam & practical evaluation. (Level 1) and GE-EHS-466/466R (Level 2)
• Upon classroom training completion: GE-EHS-465-
• Aspects to cover in classroom training & practical CLSRM (Level 1) and GE-EHS-466-CLSRM (Level 2)
evaluations are explicated in the GE Crane Manual. • Upon practical training completion: GE-EHS-465-
PRACT (Level 1) and GE-EHS-466-PRACT (Level 2)
• Trainers must have suitable technical & operational
• External Train-the-trainer completion code: GE-EHS-
experience (locations to document qualifications). 465T-CLSRM

• Online courses available in GE Learning to support online Work with or around mobile cranes:
instruction (may also be used for team members). • Online initial/refresher courses: GE-EHS-220/220R
• Classroom training completion: GE-EHS-220-CLSRM
• GE Learning course codes available to document
• Upon practical training completion: GE-EHS-220A-
completion of practical evaluations. Level1-CLSRM and GE-EHS-220A-Level 2-CLSRM

• Re-fresher training at least every 3 years, and include both

online or classroom training and a practical evaluation.

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7.1 Cranes & Hoists
7.1.3 – ALL – Tier 2
Do the GE employees, and GE supervised contractors, conduct required pre-use
inspections prior to using lifting devices, cranes or hoists?

Inspection shall be conducted by a • Conduct a pre-lift safety check prior to proceeding with
competent person, do not require
documentation, and shall be the lift. E.g. pre-work P.I.C.K checklist, pocket card with
consistent with GE, manufacturers, pre-work reminders, posters, etc.
and regulatory requirements.

Each lifting device, rigging, crane and • A common practice is to identify higher risk equipment in
hoist shall have an inspection by the the inventory and post visual aid directly on the lifting
GE employee or GE supervised device/ equipment.
contractor prior to use. This includes
lifting devices, rigging, cranes and
hoists owned or leased by GE, as well • GE Crane Manual lists control points for various types of
as the those owned or leased by the cranes, slings & riggings, etc.
GE customer and used by GE.

• All Non-Routine - Critical, Engineered and New/Modified

Product Lifts require a pre-lift meeting.

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PICK – How to Lift Safely
Plan Inspect
All lifting operations should have a SRA or Lift Visual inspection checks on cranes should be
Plan in place completed before use
A pre lift meeting or brief communication should be All lifting equipment to be used should be visually
held prior to lifting commencing. inspected prior to use.
The weight of the load should be verified and the Damaged equipment should be quarantined and
Centre of Gravity identified. removed from service.
The Crane Operator has the final say at all times.

Check the environment Keep Looking & Listening

Check lift area, path of travel and landing area to Be aware of changing condition, or conditions not
verify no obstructions or blocked aisles. Includes anticipated in the lift planning.
unobstructed access to emergency exits.
Verify that barriers and defences are still intact and
Path of travel should be as low as possible. that unauthorised personnel do not re-enter the
exclusion zone surrounding the lift.
Barrier off areas as required.
Upon hearing the STOP command, seeing an unclear
Under no circumstances should a load be lifted or command, or if any conditions change, STOP WORK
carried over personnel. and re-evaluate the lift prior to proceeding.

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Examples of pre-use checks materials
More on P.I.C.K.:
• GE Crane Manual Appendix 1.
• P.I.C.K. deck with links & videos.

Inspection pads and

high visibility signage

Leveraged from: GE Aviation

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Good practice: Sling inspection poster

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Video: Keep Looking & Listening!

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7.1 Cranes & Hoists
7.1.4/7.1.4d – FFDW/OO – Tier 2
Does the Organisation conduct monthly inspections as required by the GE Crane
Safety Manual?

These inspections may be conducted

by operators or other personnel with • Documented monthly inspections required for
sufficient experience and competency. Cranes/Hoist and Mobile Cranes.
See the inspection requirements
outlined in the GE Crane Safety
Manual for additional guidance. • Not required for Rigging/Attachments unless local
regulations are more stringent.
Distributed workforces shall conduct
a pre-use inspection for all cranes and
hoists owned or leased by customers • Equipment must be marked to indicate it is approved
which are used by GE or GE for use (e.g. coloured types or rope as a marking on
supervised contractors to satisfy this
monthly requirement. the equipment for each month and/or year).

Documentation for the inspection • Records for documented Inspections must be

may be maintained in the
preventative maintenance system or maintained for the current year and previous 5 years.
equivalent.
• Gensuite tools such as Power Inspection Tool or
Compliance Calendar may be used.

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Overhead/mobile crane inspections
Examples of Overhead or Mobile Crane
inspections available in Appendices 8 & 9
of the GE Crane Manual.

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7.1 Cranes & Hoists
7.1.5 – ALL – Tier 2
Does the Organisation ensure Annual Thorough Examinations are conducted as
required by the GE Crane Safety Manual?

The thorough examination is the • Documented Annual Thorough Examinations required

annual inspection described in the GE
Crane Safety Manual, which shall be for all types of lifting equipment.
conducted by a qualified individual.
A qualified individual is one who has • May be more frequent if local regulations are more
appropriate certification or stringent (and/or as indicated by manufacturer).
documented technical competency to
conduct inspections of the type of
crane system being inspected. • Lifting equipment may also require a Thorough
Examination in other circumstances, such as:
This is a 1-deficiency question. o Brought into use for the first time, unless
accompanied by valid regulatory documentation.
o Involved in an incident or dangerous occurrence.
o After 6 months or longer without of use, etc.

• Equipment must be marked to indicate it is approved

for use (e.g. coloured types or rope as a marking on
the equipment for each month and/or year).

• Records for documented Inspections must be

maintained for the current year and previous 5 years.
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Cranes & Hoists: inspection summary
GE Crane Manual specifies different inspection requirements.

Below is the Minimum expected, always check applicable

regulations for more stringent expectations...
• Pre-use Inspection (do not need to be documented)
May be done by crane operator through a visual check of all
components prior to use/ lift.
• Monthly Inspection (must be documented & archived 5Y)
Must be done by a competent person and documented with a
checklist or equivalent .
• Annual Examination (must be documented & archived 5Y)
Must be done by a qualified person and documented by a
report or equivalent .

Defects identified must be documented & corrective actions

tracked to closure.
Any defects that could become a danger must result in the
equipment being taken out of service until properly addressed.

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7.1 Cranes & Hoists
7.1.6 – DW – Tier 2
Where the Organisation plans to use the GE customer owned or leased cranes,
hoists, or lifting equipment, has the organization collected inspection documentation
of the equipment prior to using the equipment at the GE customer's location?

If the crane or hoist is owned or

leased by a GE Customer, then a
review of the most recent monthly • Applies to Customer or supplier owned lifting equipment.
and annual inspection documentation
from the customer is required to
ensure the device has been properly
• Process for GE to obtain the inspection information from
maintained. the owner of the crane/hoist may be through the ITO Phase
or pre-mobilization process.
GE employees and GE supervised
contractors shall also perform a pre-
use inspection in addition to this
• Documented review prior to using by a Competent person,
review as a verification of the unit's including checking for a valid test certificate.
functionality.
• Written permission must be received from customer if GE
This is a 1-deficiency question.
personnel are required to use their lifting equipment.

• Pre-use inspections by trained operators still apply.

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Good practice: PGS Guidance for Service

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Cranes & Hoists: driving behaviour
A lifting operation is not a simple one!
Seems like it could be, we do that routinely… But human and financial
consequences in the event of an accident can be dramatic!

Change the Behaviour

• Training Acting on all those aspects

• Audit during Lift operations will change the behaviour of
• Documentation reviews employees affected by the
• Safety talks lifting operations.
• SRA training
• Lift Plans But driving the behaviour of
• Supervisor involvement all employees around lifting
• Professional Competency operations is of similar
• Material inspections importance!
• Materials conditions

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Safety Moments

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Cranes & Hoists: to go further…
Support Resources
• GE Crane Manual & translations
• Cranes & Hoists FW training video
• E7.1 transition & guidance materials
• EU/SSA Shared Service (H&S CoE)

Gensuite Tools
• Risk Assessment (simplified/ enhanced assessments)
• Safety Matrix (inventory of jobs, tasks, activities)
• Training Tracker (personnel & contractor training)
• Power Inspection Tool/ Compliance Calendar
(monthly & annual inspections, regulatory controls)
• Action Tracking System, Concern Reports
(verification process, strengths of defences)

Shared Service CoEs typical support

• Provide guidance on GE Crane Safety Manual, incl. crane inventory and GE lifting standards.
• Review lift plans or Risk Assessments for lifting operations, advise on improvements.
• Support implementation of defences for safe use of Lifting and Material Handling Equipment.

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Live demo: Electronic Crane Lift Plan Tool

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