{"id":4760,"date":"2026-04-07T09:40:13","date_gmt":"2026-04-07T07:40:13","guid":{"rendered":"https:\/\/pilz-magazine.com\/de\/?p=4760"},"modified":"2026-04-16T10:36:12","modified_gmt":"2026-04-16T08:36:12","slug":"machine-safety-training-crane-retrofit","status":"publish","type":"post","link":"https:\/\/pilz-magazine.com\/en\/machine-safety-training-crane-retrofit\/","title":{"rendered":"Safety for overhead cranes"},"content":{"rendered":"\n<p>Injec\u00adtion moulding machines are cen\u00adtral com\u00adpo\u00adnents on some pro\u00adduc\u00adtion lines at Marelli Mako and each new product run involves retooling mea\u00adsures to some extent. Bridge cranes then trans\u00adport the moulds that workers have dis\u00adman\u00adtled and bring in the tools and equip\u00adment required for a new series.&nbsp; Over\u00adhead cranes move loads, such as tools, at high speed and deliver them pre\u00adcisely, safely and just in time to the spec\u00adi\u00adfied des\u00adti\u00adna\u00adtion. Set-up changes are to happen quickly. Down\u00adtime is not an option, as it costs money. At no time must there be any danger to the oper\u00adating per\u00adsonnel beneath the trans\u00adported loads. That\u2019s why spe\u00adcial safety pre\u00adcau\u00adtions apply to over\u00adhead or bridge cranes.<\/p>\n\n\n\n<div class=\"wp-block-group alignwide is-layout-constrained wp-block-group-is-layout-constrained\">\n<div class=\"m2g-video-container\" style=\" background-image: url(https:\/\/pilz-magazine.com\/de\/wp-content\/uploads\/sites\/23\/2026\/04\/Thumbnail_Animation-1.webp);\"><div class=\"embed-privacy-container is-disabled embed-vimeo\" data-embed-id=\"oembed_e474f2b4547a758bf1e414d5bbc6ddbf\" data-embed-provider=\"vimeo\" style=\"aspect-ratio: 800\/450;\">\t\t\t\t\t\t<button type=\"button\" class=\"embed-privacy-enable screen-reader-text\">Display content from Vimeo<\/button>\t\t\t\t\t\t<div class=\"embed-privacy-overlay\">\t\t\t\t<div class=\"embed-privacy-inner\">\t\t\t\t\t<div class=\"embed-privacy-logo\" style=\"background-image: url(https:\/\/pilz-magazine.com\/en\/wp-content\/plugins\/embed-privacy\/assets\/images\/embed-vimeo.png?ver=1778830924);\"><\/div>\t\t<p>\t\tClick here to view the con\u00adtent from Vimeo.\t\t\t\t\t<br>\t\t\t\t\tLearn more in <a href=\"https:\/\/vimeo.com\/privacy\" target=\"_blank\">Vimeo\u2019s pri\u00advacy policy<\/a>.\t\t<\/p>\t\t<p class=\"embed-privacy-input-wrapper\">\t\t\t<input id=\"embed-privacy-store-vimeo-e474f2b4547a758bf1e414d5bbc6ddbf\" type=\"checkbox\" value=\"1\" class=\"embed-privacy-input\" data-embed-provider=\"vimeo\">\t\t\t<label for=\"embed-privacy-store-vimeo-e474f2b4547a758bf1e414d5bbc6ddbf\" class=\"embed-privacy-label\" data-embed-provider=\"vimeo\">\t\t\t\tAlways dis\u00adplay con\u00adtent from Vimeo\t\t\t<\/label>\t\t<\/p>\t\t\t\t\t\t<\/div>\t\t\t\t\t\t\t\t<div class=\"embed-privacy-footer\"><span class=\"embed-privacy-url\"><a href=\"https:\/\/player.vimeo.com\/video\/1181496984?dnt=1\">Open Video directly<\/a><\/span><\/div>\t\t\t<\/div>\t\t\t\t\t\t<div class=\"embed-privacy-content\">\t\t\t\t<script>var _oembed_e474f2b4547a758bf1e414d5bbc6ddbf = '{\\\"embed\\\":\\\"&lt;iframe class=&quot;vimeo-iframe&quot; src=&quot;https:\\\\\/\\\\\/player.vimeo.com\\\\\/video\\\\\/1181496984?dnt=1&quot; width=&quot;800&quot; height=&quot;450&quot; frameborder=&quot;0&quot; allowfullscreen=&quot;allowfullscreen&quot;&gt;&lt;\\\\\/iframe&gt;\\\"}';<\/script>\t\t\t<\/div>\t\t<\/div><\/div>\n\n\n\n\n<p>Pilz also ensures the pro\u00adduc\u00adtive safety of auto\u00admated guided vehicle sys\u00adtems \u2013 from devel\u00adop\u00adment of the system con\u00adcept through to com\u00admis\u00adsioning.<\/p>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Risk analysis for a sustainable crane safety concept<\/h2>\n\n\n\n<p>When retro\u00adfits became due back in 2024, Marelli Mako included safety aspects on its to-do list, in addi\u00adtion to opti\u00admising pro\u00adduc\u00adtivity and reli\u00ada\u00adbility. Twenty over\u00adhead cranes, each with a load capacity of 16 tonnes or more, are in oper\u00ada\u00adtion at Marelli Mako 24\/7. The task: to make all the cranes fit for as many more years as pos\u00adsible, using modern automa\u00adtion and safety con\u00adcepts. The chal\u00adlenge: oper\u00ada\u00adtional processes should not be restricted for any longer than nec\u00ades\u00adsary.<\/p>\n\n\n\n<div class=\"wp-block-group mgznkr-box mgznkr-box-yellow has-background is-layout-flow wp-block-group-is-layout-flow\" style=\"background-color:#fddf8c\">\n<h3 class=\"wp-block-heading has-background\" id=\"boxinhalt-hier-einfugen\" style=\"background-color:#fbb900\">Marelli Mako<\/h3>\n\n\n\n<p>Marelli Mako Elek\u00adtrik Sanayi ve Ticaret A.\u015e. is one of Turkey\u2019s largest auto\u00admo\u00adtive sup\u00adpliers, with around 1,600 employees.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Founded in 1970 in Bursa as Mako Elek\u00adtrik Sanayi ve Ticaret A.\u015e.<\/li>\n\n\n\n<li>From 2005: Part of the Mag\u00adneti Marelli Group<\/li>\n\n\n\n<li>2019: Merger with Cal\u00adsonic Kansei 2019 under the Marelli umbrella brand<\/li>\n\n\n\n<li>Today: The com\u00adpany oper\u00adates under the name Marelli Mako Elek\u00adtrik Sanayi ve Ticaret A.\u015e.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"boxinhalt-hier-einfugen\" style=\"margin-top:50px;margin-bottom:10px\">Portfolio<\/h3>\n\n\n\n<p style=\"margin-top:10px\">In the indus\u00adtrial park in the city of Bursa, around 100 kilo\u00adme\u00adtres from Istanbul, Marelli Mako man\u00adu\u00adfac\u00adtures wind\u00adscreen wipers, heating and fan motors, igni\u00adtion coils, fuse boxes and other com\u00adpo\u00adnents and product groups, pri\u00admarily for the auto\u00admo\u00adtive industry.<\/p>\n<\/div>\n\n\n\n<p>To ensure that the plant\u2019s over\u00adhead cranes also comply with cur\u00adrent inter\u00adna\u00adtional stan\u00addards \u2013 in par\u00adtic\u00adular EN 13135\u20131 (Cranes \u2013 Safety \u2013 Design \u2013 Require\u00adments for equip\u00adment) and EN ISO 13849\u20131 (Safety of machinery \u2013 Safety-related parts of con\u00adtrol sys\u00adtems) \u2013 the first step was to carry out a risk analysis. The result: crane oper\u00ada\u00adtion was safe, but in some respects not state-of-the-art. For example, a number of safety func\u00adtions that limit and stop the crane move\u00adments were not mon\u00adi\u00adtored by a safety con\u00adtroller. Also, the safety tech\u00adnology installed on the cranes no longer met the cur\u00adrent require\u00adments in every respect. The auto\u00admo\u00adtive sup\u00adplier could not imple\u00adment all of this by them\u00adselves. To make mat\u00adters worse, a safety update would not actu\u00adally have been fea\u00adsible without low\u00adering the entire crane tower.<\/p>\n\n\n\n<p>The deci\u00adsion-makers sought advice from Pilz, a partner of Marelli Mako since 2022, and held in high regard on all mat\u00adters relating to Safety &amp; Secu\u00adrity. The respon\u00adsible project part\u00adners at the automa\u00adtive sup\u00adplier were con\u00advinced by Pilz\u2019s approach: that the upcoming mod\u00aderni\u00adsa\u00adtion mea\u00adsures could be imple\u00admented without low\u00adering the crane \u2013 and with careful plan\u00adning, even in par\u00adallel with ongoing oper\u00ada\u00adtions. In addi\u00adtion to con\u00adcep\u00adtual advice on the sys\u00adtems in ques\u00adtion, the Pilz ser\u00advice package included the replace\u00adment and renewal of the safety tech\u00adnology, including engi\u00adneering ser\u00advices. At the heart of the solu\u00adtion is the automa\u00adtion system PSS 4000.<\/p>\n\n\n\n<figure class=\"wp-block-image alignwide size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"640\" src=\"https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-sichere-Deckenkrane-bei-Marelli-Mako-1024x640.jpg\" alt class=\"wp-image-4782\" srcset=\"https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-sichere-Deckenkrane-bei-Marelli-Mako-1024x640.jpg 1024w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-sichere-Deckenkrane-bei-Marelli-Mako-300x188.jpg 300w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-sichere-Deckenkrane-bei-Marelli-Mako-768x480.jpg 768w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-sichere-Deckenkrane-bei-Marelli-Mako-1536x960.jpg 1536w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-sichere-Deckenkrane-bei-Marelli-Mako-540x338.jpg 540w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-sichere-Deckenkrane-bei-Marelli-Mako-1080x675.jpg 1080w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-sichere-Deckenkrane-bei-Marelli-Mako.jpg 1920w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\"><figcaption class=\"wp-element-caption\">The assembly process, car\u00adried out at a height of twelve metres and with only lim\u00adited space avail\u00adable between the crane and ceiling, pre\u00adsented par\u00adtic\u00adular chal\u00adlenges. \u00a9&nbsp;Marelli Mako Elek\u00adtrik Sanayi ve Ticaret A.\u015e<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Customised automation solution<\/h2>\n\n\n\n<div class=\"wp-block-group link-pilz alignright align-outside is-layout-constrained wp-block-group-is-layout-constrained\">\n<p><a href=\"https:\/\/www.pilz.com\/en-INT\/products\/automation-system-pss-4000\" target=\"_blank\" rel=\"noreferrer noopener\">The automa\u00adtion system PSS 4000<\/a><\/p>\n<\/div>\n\n\n\n<p>At the heart of the automa\u00adtion and safety solu\u00adtion favoured by Marelli Mako is the industry-proven automa\u00adtion system PSS 4000 from Pilz. The con\u00adtroller in the system can be cus\u00adtomised using var\u00adious I\/O mod\u00adules, pro\u00adviding users with a solu\u00adtion that is tai\u00adlored pre\u00adcisely to their spe\u00adcific require\u00adment. As such, PSS 4000 is a future-proof system \u2013 including simple pro\u00adgram\u00adming based on the Pilz soft\u00adware plat\u00adform PAS4000 and web-based, intu\u00aditive diag\u00adnos\u00adtics and visu\u00adal\u00adi\u00adsa\u00adtion based on the visu\u00adal\u00adi\u00adsa\u00adtion soft\u00adware PASvisu. Building on this con\u00adcept, safety tech\u00adnology such as limit switches, emer\u00adgency stop push\u00adbut\u00adtons, drives and the con\u00adtrol cab\u00adinet were replaced.<\/p>\n\n\n\n<p>At the same time, Pilz experts inte\u00adgrated series drives in the over\u00adhead crane. In future, these will con\u00adtrol the move\u00adments of the crane car\u00adriage, trolley drive and hoist and guar\u00adantee safe shut\u00addown processes. In order to mon\u00aditor loads in real-time and diag\u00adnose faults quickly and easily, the Pilz oper\u00adator ter\u00adminal Pilz Human Machine Inter\u00adface (PMI) was inte\u00adgrated in addi\u00adtion to the visu\u00adal\u00adi\u00adsa\u00adtion soft\u00adware.<\/p>\n\n\n\n<div class=\"wp-block-group link-pilz alignright align-outside is-layout-constrained wp-block-group-is-layout-constrained\">\n<div class=\"wp-block-group is-layout-constrained wp-block-group-is-layout-constrained\">\n<p><a href=\"https:\/\/www.pilz.com\/en-INT\/products\/operating-and-monitoring\/operator-terminals\" target=\"_blank\" rel=\"noreferrer noopener\">Oper\u00adator devices \/ oper\u00adator ter\u00admi\u00adnals PMI \u2014 HMI with PMI<\/a><\/p>\n<\/div>\n<\/div>\n\n\n\n<p>As expected, the project posed sig\u00adnif\u00adi\u00adcant chal\u00adlenges in var\u00adious areas. As the crane system serves a total of nine injec\u00adtion moulding machines and the plant was not to be shut down for longer than absolutely nec\u00ades\u00adsary, plan\u00adning had to be care\u00adfully coor\u00addi\u00adnated within a tight time frame. Pilz did actu\u00adally manage to avoid the time-con\u00adsuming and costly process of low\u00adering the crane tower: Pilz suc\u00adcess\u00adfully car\u00adried out the entire assembly process at great height and with only lim\u00adited space avail\u00adable between the crane and ceiling.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"640\" src=\"https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-Automatisierungssystem-PSS4000-bei-Marelli-Mako-1024x640.jpg\" alt class=\"wp-image-4783\" srcset=\"https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-Automatisierungssystem-PSS4000-bei-Marelli-Mako-1024x640.jpg 1024w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-Automatisierungssystem-PSS4000-bei-Marelli-Mako-300x188.jpg 300w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-Automatisierungssystem-PSS4000-bei-Marelli-Mako-768x480.jpg 768w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-Automatisierungssystem-PSS4000-bei-Marelli-Mako-1536x960.jpg 1536w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-Automatisierungssystem-PSS4000-bei-Marelli-Mako-540x338.jpg 540w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-Automatisierungssystem-PSS4000-bei-Marelli-Mako-1080x675.jpg 1080w, https:\/\/pilz-magazine.com\/en\/wp-content\/uploads\/sites\/24\/2026\/03\/Pilz-Automatisierungssystem-PSS4000-bei-Marelli-Mako.jpg 1920w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\"><figcaption class=\"wp-element-caption\">Automa\u00adtion system PSS 4000 from Pilz: I\/O mod\u00adules with exactly the func\u00adtions that are needed are lined up in the con\u00adtrol cab\u00adinet. \u00a9&nbsp;Marelli Mako Elek\u00adtrik Sanayi ve Ticaret A.\u015e<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Real-time monitoring for greater safety<\/h2>\n\n\n\n<p>The new automa\u00adtion solu\u00adtion, including the installed Pilz safety tech\u00adnology, now allows crane oper\u00ada\u00adtion to be mon\u00adi\u00adtored in real-time. Fea\u00adtures that did not exist before include an over\u00adload con\u00adtrol system, safe speed mon\u00adi\u00adtoring of the hook drive, safe shut\u00addown archi\u00adtec\u00adture, safety con\u00adnec\u00adtion archi\u00adtec\u00adture in accor\u00addance with EN ISO 13849\u20131 and a diag\u00adnostic dis\u00adplay for easy trou\u00adbleshooting and main\u00adte\u00adnance. The emer\u00adgency stop system has also been opti\u00admised: the EN ISO 13850-com\u00adpliant PITestop emer\u00adgency stop push\u00adbut\u00adtons have been inte\u00adgrated into the crane system, allowing oper\u00ada\u00adtors to put the system into a safe state imme\u00addi\u00adately in the event of danger. This func\u00adtion increases human safety in the vicinity of the plant as well as the reli\u00ada\u00adbility of the overall system. \u201cIn the course of the project, our employees have become more aware of machinery safety and the impor\u00adtance of safety func\u00adtions. In addi\u00adtion, the inte\u00adgra\u00adtion of modern tech\u00adnolo\u00adgies in our sys\u00adtems guar\u00adan\u00adtees a high level of safety for everyone involved,\u201d says Muhammet Ali \u0130\u00c7\u0130N, OHS spe\u00adcialist (Occu\u00adpa\u00adtional Health and Safety) at Marelli Mako, sum\u00admarising.<\/p>\n\n\n\n<div class=\"wp-block-group is-layout-constrained wp-block-group-is-layout-constrained\">\n<blockquote class=\"wp-block-quote has-text-align-center is-style-large is-layout-flow wp-block-quote-is-layout-flow\">\n<p>\u201eThroughout the entire project phase, Pilz con\u00adfirmed our trust in them with a sup\u00adportive and solu\u00adtion-ori\u00aden\u00adtated approach.\u201c<\/p>\n<cite>Muhammet Ali \u0130\u00c7\u0130N<\/cite><\/blockquote>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Lower risk of accidents and fewer downtimes<\/h2>\n\n\n\n<p>The advan\u00adtages for Marelli Mako and the oper\u00adating per\u00adsonnel are obvious: the mod\u00adernised cranes guar\u00adantee safe oper\u00ada\u00adtion and reduce the risk of acci\u00addents. For Marelli Mako, there is no sub\u00adsti\u00adtute for working with Pilz: Pilz is a con\u00adsul\u00adtant, ser\u00advice provider and tech\u00adnology sup\u00adplier \u2013 with com\u00adpre\u00adhen\u00adsive exper\u00adtise in machinery safety, stan\u00addards, reg\u00adu\u00adla\u00adtions and global net\u00adworking. And for Muhammet Ali \u0130\u00c7\u0130N, the automa\u00adtion system PSS 4000 from Pilz is the ideal solu\u00adtion for all safety issues. \u201cPilz has met our expec\u00adta\u00adtions in every respect. Our col\u00adleagues at Pilz are com\u00adpe\u00adtent and com\u00admitted. The col\u00adlab\u00ado\u00adra\u00adtion was pro\u00adfes\u00adsional and on an equal basis at all times. Throughout the entire project phase, Pilz con\u00adfirmed our trust in them with a sup\u00adportive and solu\u00adtion-ori\u00aden\u00adtated approach. We worked very well together to imple\u00adment inno\u00adv\u00ada\u00adtive solu\u00adtions and over\u00adcome crit\u00adical issues, and will con\u00adtinue to do so in future,\u201d says Muhammet Ali \u0130\u00c7\u0130N, con\u00advinced.<\/p>\n\n\n\n<div class=\"wp-block-group link-pilz is-layout-constrained wp-block-group-is-layout-constrained\">\n<p><a href=\"https:\/\/www.pilz.com\/en-INT\/trainings\" target=\"_blank\" rel=\"noreferrer noopener\">More about training courses on plant\/machinery safety at Pilz<\/a><\/p>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Cranes are an inte\u00adgral part of the pro\u00adduc\u00adtion and logis\u00adtics chain at Marelli Mako Elek\u00adtrik Sanayi ve Ticaret A.\u015e. They must be safe, so that loads sus\u00adpended over\u00adhead do not pose any danger to oper\u00adating per\u00adsonnel. With com\u00adpre\u00adhen\u00adsive exper\u00adtise, Pilz has brought the first of sev\u00aderal cranes up to the cur\u00adrent stan\u00addards. <\/p>\n","protected":false},"author":29,"featured_media":4785,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"wp_typography_post_enhancements_disabled":false,"footnotes":""},"categories":[71,13,79,15,78],"tags":[],"class_list":["post-4760","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-dienstleistungen","category-knowledge","category-not-on-start","category-services","category-special-hmi-2026"],"acf":[],"_links":{"self":[{"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/posts\/4760","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/users\/29"}],"replies":[{"embeddable":true,"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/comments?post=4760"}],"version-history":[{"count":4,"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/posts\/4760\/revisions"}],"predecessor-version":[{"id":4866,"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/posts\/4760\/revisions\/4866"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/media\/4785"}],"wp:attachment":[{"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/media?parent=4760"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/categories?post=4760"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/pilz-magazine.com\/en\/wp-json\/wp\/v2\/tags?post=4760"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}