CRANE SYSTEM DIRECTIVESSafety of machinery

Risk assessment LVD Test EMC Test

Machinery (MD) Directive

2006/42/ECEN ISO 12100:2010

EN -ISO DIN FEM EN -ISO DIN FEM305/2011/EU Construction

Products Regulation

Cranes - Bridge and

gantry cranes   EN 15011+A1

Limiting and indicating

devicesEN 12077-2+A1

Low voltage (LVD)

Directive 2014/35/EUEN 60204-1 Welding coordination EN ISO 14731

Cranes - General

designEN 13001 – 1

Rotating electrical

machines  EN 60034-1

Electromagnetic Compatibility

(EMC) Directive 2014/30/EU

  EN 61000-4-2 Electro 

static discharge(ESD)Welder Qualification EN ISO 9606-1

Crane safety - General

design - Part 2: Load EN 13001 – 2

Safety of machinery -

Safety-related parts of EN ISO 13849-1

Noise Emission by Outdoor

Equipment Directive 2000/14/EC EN ISO 11688

EN 61000-4-4

Electrical Fast WPS EN ISO 15609-1

Rules For The Design

Of Hoisting AppliancesFEM 1.001

Safety of machinery -

Electrical equipment of EN 60204–32

6331 Health and Safety

Conditions Regulation for the Use

  EN 61000-4-5 Surge 

Transients

Welding Procedure

Qualification

EN ISO 15613 &

EN ISO 15614-1

Measures For

Achieving Safe FEM 9.755

Cranes - Controls and

control stationsEN 13557

EN 61000-4-11 Voltage

dips,short interruptions

Welding Operator

QualificationEN ISO 14732

Power Driven Series -

Security FEM 9.751

Low Voltage

Adjustable Frequency FEM 9.752

EN 55011(Contuded

emission)Ndt-personel EN ISO 9712

Hand And Power

Driven Hoists For FEM 9.756

Safety of machinery -

Emergency stopEN ISO 13850

EN 55011 (Radiated

emission)Joint preparation EN ISO 9692-1&2

Cranes - Test and

inspection procedures

TS 10116

TS ISO 9927-1

rotating electrical

machines (IP code); EN 60034-5

EN 61000-4-6

Contucted Immunity

Inspection &Testing

during welding EN ISO 13916

Steel wire ropesEN 12385-4 &

CEN/TS 13001-3-2

Graphical Symbols For

Control DevicesFEM 9.941

EN 61000-3-2

Harmonics

Cranes - Access EN 13586Selection Of Lifting And

Travel MotorsFEM 9.683 EN 61000-3-3 Flicker Ndt -general rules EN ISO 17635

Acceptance levels for

NDT

Cranes- Safe Use ISO 12480-1 Visual Testing EN ISO 17637 EN ISO 5817

Terminations for steel

wire ropes

EN 13411

(1-2-3-4-5-6-7-8)

Founding - Spheroidal

graphite cast ironsEN 1563 Radiographic testing EN ISO 17636-1&2 EN ISO 10675-1&2

Hook & Hook

TraversenTS 2340

DIN 15401

DIN15402

Steel castings - Steel

castings for general EN 10293 Ultrasonic Testing

EN ISO

17640,10863,13588 &

EN ISO

11666,15626,22825,232

Cranes- Wire Ropes ISO 4309 EN -ISO Cold formed EN 10219-1Magnetic particle

testingEN ISO 17638 EN ISO 23278

Cranes - Safety -

Design - Requirements EN 13135

Cranes - Competency

requirements for crane ISO 23814

Quenched and

tempered steelsEN 10083-1 ,2,3

Makro &microscopic

testingEN ISO 17639 EN ISO 5817

Cranes - Information for

use and testing

TS EN 12644-1+A1

EN 12644-2 +A1

Cranes - Monitoring for

crane design working ISO 12482 Surface preparation ISO 8501 ,ISO 8503 Case hardening steels EN 10084

Quality levels for

cuttingEN ISO 9013

Wheel shafts DIN 15091 Cranes-Classification  TS ISO 4301–5 Paint application ISO 12944Hot rolled products of

structural steelsEN 10025-1 ,2 Group of materials CEN ISO /TR 15608

Cranes; steel

structures; verification

DIN 15018-1

DIN 15018-2

Technical

characteristics and ISO 7363

Lifting appliances;

groove profiles for wire DIN15061-1

Cranes - Tolerances for

wheels and travel and ISO 12488-1

Wheel Group DIN 15090

DIN 15074

Crane supporting

structuresTS EN 1993-6

Classification Of

MechanismsISO 4301 FEM 9.511

Asymmetric wedge

socketTS EN 13411-6+A1

Rules For The Design -

Local Girder StressesFEM 9.341

Limit States and proof

competence of steel EN 13001-3-1

Dimensions And

Design Of Rope FEM 9.661

Cranes - Stiffness -

Bridge and gantry TS ISO 22986

Lifting Force Limiters

For Controlling FEM 9.761

Cranes-Training of

driversTS ISO 9926-1

Surface preparation and paint standards

GÜRALP CRANE SYSTEM DIRECTIVES & STANDARDS 2017

ISO 3834-2 &EN 1090-1,2

Inspection &Testing after welding

QUALITY REQUIREMENTS for welding

Mechanical Design Standard Electrical Design Standard

DESIGN STANDARDS

Mechanical Design Standard

DNA of QUALITY

All raw materials are checked and approved by quality staff after than all following test;

Dimentional checks (acc. standarts) Material Checks

Visual Via NDT Methods

Via Destructive test (Chemical analyses and mechanical tests)

1.1 Raw Material Controls

2.1 Machining Process Controls

All semi finished product are checked and approved by quality staff ;

Dimentional checks (acc. drawings) o Machining process starts after first part approved by quality staff o Production goes on with periodically controlls by quality staff Note : We’ll be set up SPC Controls Charts after traning process finished

Welding Quality Acceptance Criteria : TS EN ISO 5817-B

2.1 Machining Process Controls

All semi finished product are checked and approved by quality staff ;

Dimentional checks (acc. drawings) o Machining process starts after first part approved by quality staff o Production goes on with periodically controlls by quality staff Note : We’ll be set up SPC Controls Charts after traning process finished

2.2 Hoist and Bridge Production Controls

After the control process all semi finished & and finished product (Endcarriages,bodies etc) are labeled and identified by quality staff

in this wise it’s provided the separation of non-conforming products with the appropriate product at shop floor.

DIN CUP 4

All painted products controlled and results recorded as in (F105_2 ) PAINT TEST REPORT

o Dın-cup 4 viscosity test (Paint Prepreparation) o Surface Treatment Controls (Acc to ISO 8501-1) o Visual controls (Colour, paint defects etc.) o Paint Thickness Controls o Cross cut adhesion test ( acc to ISO 2409)

2.3 Painting Process Controls (Acc. to TS EN ISO 12944)

3.1 FINAL CONTROL and LOAD TESTS

Acc to TS EN 15011+A1 (1.1 Dynamic, Static 1.25) standart all finished hoists are tested at final load test station.

Test results are documentated as in FINAL TEST REPORT (F074_3)

3.2 FINAL TESTS

All finished hoists , endcarriages etc. are throughout examinated by quality staff Test results are documentated as in FINAL TEST REPORT (F074_3)

All finished systems are controlled via checklist by quality staff acc to product list Results are documentated as final shipment control checklist. and also items proof photos are taken and recorded

After assembly operation at site all systems are made load tests acc to TS EN 15011+A1 (1.1 Dynamic, Static 1.25)

All required measurements are taken than results are recorded as in ‘‘F056_4_StartupAndJobFinishingForm

Self Desinged Load Test Station Portative Hardness Measurement Device (Krautkramer MIC 20) Portative Spectrometer Analysis Device (Test Master Pro) Ultrasonic NDT Test Device (Krautkramer USM 35 X) Magnetic NDT Test Device(Magnaflux) Penetrant Test Kit (LVD) Low Voltage Directive Test Device (Metrel MI 2094) Total Station Leika TS 09 Plus Dimensional measuring instruments Nivo Lasermeter Caliper Mikrometer Comparator Other Measurement Devices Elcometer Paint Thickness Measurement Device Temperature and humidity meter Multimeter

Raw material analysis via

spectrometer

Construction 3D measurements

Before and after heat treatment

raw material hardness controls

Raw material internal structure

discontinuity control with

Ultrasonic Test

LVD Low Voltage Test

Static ve Dinamic Load Tests

Material non-destructive inspections

Inspection of machined products

GURALP CRANE HAVE INVESTED NEW INVESTMENTS IN THE QUALITY LABORATORY THAT HAS BEEN MADE TO IMPROVE THE IMPROVEMENT OF HIGH PRODUCT QUALITY AND STANDARDS.

1. Zwick Z250SR Tensile Test Equipment

2. Portable 3D (CMM) Dimention Control Equipment

3. MICROHARDNESS MEASUREMENT DEVICE

4. STEREO MACROSCOPE

• Welding macro controls • Raw material macro structure controls ( Nodular cast iron etc..) • Investigation of failure surface

Welding Macro Dimentional Controls

Cast iron nodularity and flake analysis

Surface examination, coating thickness measurement

VT __LEVEL 2

PT __LEVEL 2

MT__LEVEL 2

UT __LEVEL 2

RT __LEVEL 2

68 certificated welding operator acc. to approved by TUV AVUST.

(EN ISO 9606-1 , ISO 14732)

EN ISO 3834-2 Welding Competency Certificate_ TUV AVUST.

WPQR approved by TUV

Approved welding procedures acc to ISO 4063

135- Gas Shielded Metal Arc Welding

111- Metal Arc Welding via Covered Electrode

121- Submerged Arc Welding

Visual Inspection (VT) Penetrant Inspection(PT)

Magnetic Particles Inspection (MT) Ultrasonic Inspection (UT)

All finished hoists are tested at final load test station

Acc to TS EN 15011+A1 (1.1 Dynamic, Static 1.25), FEM.1001 (1.25 Dynamic, Static 1.4)

CERTIFICATES Notified Body

TS EN ISO 9001:2008: Quality Management System TÜV

ISO 3834–2/EN 729-2 :Desing production construction and

erection of steel in compliance with the requirements TÜV

EN 1090 - 1 & 2 Welding Competency Certificate TÜV

TS EN 15011 Cranes - Bridge and gantry cranes TSE

HYB ‘Service Qualification Certificate’ TSE

Voluntary verification of conformity

According to machinery directive 2006/42/EC TUV-NORD

Certificated welders approved by certified company TÜV

Trademark (GÜRALP) TPE

FEM Membership Certificate İSDER

1. In Güralp , Records related to faults in all processes are recorded and monitored, root cause analysis is performed, and permanent actions and mistakes are prevented from being repaired (non-conformity follow-up tables)

Problemi tanımla A

Define problem

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

Bu Yüzden / Therefore

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

A

Bu Yüzden/

Therefore B

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

Bu Yüzden / Therefore A

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

C

Bu Yüzden / Therefore B

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

Bu Yüzden/

Therefore

C

* Talaşlı imalata parça resmi ulaşmaması

* Ara bağlantı parçasının proje tarafından stok kodu bazında tanımlanmamış 

olması sebebiyle parça üretilmeden de üretim sonu kaydı yapılması

* Özel ara bağlantı parçasının ayrıca stok kodunun olmaması sebebiyle 

sevkiyat listelerinde yer almaması

Parçaya ait stok kodu netsis

üzerinde direk montajının

içerisine hammadde olarak

yedirildiğinden üretim sonu kaydı

yapılabilmiş

NEDEN? / WHY?

Ana

Sebep

Root

Causes

5 Neden Analizinin Yapıldığı

Tarih /The Date of 5-Why Analysis

06.12.2016

Sistemsel ana sebebi araştırmak için bu yolu

izleyin

Use this path to investigate the systemic root cause

stok kodu bazındaki parçalar

üretim sonu kaydı yapılarak

üretildiği netsiste kayıt altına

alınmakta

Ref. No.

Çıkarılan Dersler / Lessons Learned :

KÖK NEDEN ANALİZİ VE ALINANCAK AKSİYONLAR BELİRLENDİ

Katılımcılar / Participants:

NAZIM KANDEMİR ÖMÜR ÇEVİR

HALİL DEMİRCİ MEHMET N.

ORHAN

BEKTAŞ AVCIOĞLU ERDEM KURTMEN

Bildirim Tarihi/

Communicate to Manufacturer

06.12.2016

Müşteri / Customer

TAI

NEDEN? / WHY?

NEDEN? / WHY? NEDEN? / WHY?

NEDEN? / WHY?

Ürün - Proses / Product /

Process

PERGEL VİNÇ SİSTEMİ

2) Proje bölümü dosyalarının ilgili

bölümlere dağıtılması

sağlayacak/Erdem KURTMEN

NEDEN? / WHY?

NEDEN? / WHY?

makine montaj bölümün

standart makine toplamışParça talaşlı imalatta kalmış

NEDEN? / WHY? NEDEN? / WHY?

NEDEN? / WHY?

Uygunsuzluğun neden saptanamadığını

araştırmak için bu yolu izleyin

Use this path to investigate why the problem was

not detected

Proje dosyası ulaşmadığı için

iş makine montajı emrine göre

yapılmış

Talaşlı imalata parça resmi

ulaşmadığı için parça talaşlı

imalatta üretilmemiş

NEDEN? / WHY?

sevkiyat esnasında

kontrolleri Sevkiyat kontrol

listelerinde göre yapılmakta

NEDEN? / WHY?

Bu iş için tasarlanmış bağlantı

plakası sevkiyat listelerinde

gözükmemektedir.

NEDEN? / WHY?

TUSAS AN.16.0298 nolu işde

standart ara bağlantı plakası

sahaya gönderilmiş

TUSAS AN.16.0298 nolu işin

proje tarafından özel

tasarlanan ara bağlantı

plakası üretilmemiş

NEDEN? / WHY? NEDEN? / WHY?

Düzeltici Faaliyet / Sorumlusu

Corrective Action / Responsibility

Aksiyonların takip edildiği son tarih

The current date of action follow-up

1) Proje bölümü teknik resimlerde ve

netsiste ilgili parçaların stok kodu

bazında tanımlarının yapılmasını

sağlayacak /Erdem KURTMEN

5 Neden Analizi - 5 Why Analysis

Schmalz’ın taşıyıcı arabası

ile bizim makinanın mapa

delikleri uyuşmamaktadır

Tanımlanmış uygunsuzlukları araştırmak için

bu yolu izleyin

Use this path for the specific nonconformance being

investigated

In Güralp, all details regarding product performance and after-service services are recorded and analyzed and followed up.

1. Trainings were completed. 2. 5S regions were defined.(Layout) 3. 5S audit plans and audit checklists will be prepared to be commissioned

1. Tranings will be organized. 2. SPC control charts will be prepared 3. SPC charts will be implemented at

machining shop

GÜRALP KALITE