A failed hoist can bring operations to a standstill—posing safety risks, delaying production, and affecting your bottom line. It’s a serious problem, and when it happens, the goal immediately becomes restoring safe and efficient operations, as quickly as possible.
In these cases, having a clear action plan and the right repair partner can make all the difference in getting things back on track. MMI Hoist, a division of MMI Industrial & Steel, specializes in emergency crane and hoist repairs. Our team is trained to respond quickly, assess the situation thoroughly, and resolve issues safely.
Managing Hoist Failures: Step-By-Step
Here’s a step-by-step guide to managing a hoist failure in a way that minimizes downtime.
Step 1: Ensure Safety First
The moment a hoist fails, operations must stop immediately. Secure any suspended loads. Lock out and tag out the system to prevent accidental use during inspection or repair. Follow all OSHA safety protocols and site-specific procedures before troubleshooting. Not only does this safety-focused approach protect personnel and equipment, it also lays the groundwork for a smoother repair process.
Step 2: Contact a Qualified Crane Service Provider
When you’re facing an emergency, time matters. Reach out to an experienced crane repair partner with proven expertise in hoist repairs—like MMI Hoist. Our emergency response team includes trained, certified technicians who have access to diagnostic equipment, high-demand parts, and essential tools. We can mobilize quickly and help you start fixing the problem sooner.
Step 3: Conduct a Rapid On-Site Assessment
An experienced technician will arrive on-site to assess the equipment and determine the root cause of hoist failure. Common issues include worn brakes, faulty wiring, damaged ropes, or motor malfunction. This detailed inspection helps pinpoint the exact cause of the failure, which is essential for selecting the right repair approach and avoiding costly mistakes.
Step 4: Implement Temporary Repairs if Appropriate
When production simply cannot wait, and when it is safe and compliant to do so, short-term solutions may be implemented to restore partial or limited function. These temporary fixes may include quick component swaps or control panel workarounds. They should never be used as a substitute for actual repair, but they can help buy valuable time in an emergency.
It’s important to remember that these temporary repairs must be performed with strict attention to safety standards, and should only be used when appropriate to the situation.
Step 5: Order and Install OEM Replacement Parts
For long-term reliability, Original Equipment Manufacturer (OEM) parts are critical. These parts are much more likely to restore proper function in the equipment. Whether you’re replacing motors, brakes, control systems, or other structural components, high-quality parts will help get you back to optimal performance. Once the necessary components are sourced, schedule repair/installation during a downtime window in order to limit further disruption.
Step 6: Test, Inspect, and Certify
After repairs, comprehensive testing and a full safety inspection should be performed. Re-certification ensures the crane meets all safety standards, is operating within regulatory guidelines, and is ready for continued use. Make sure you secure documentation of work performed so that your internal records are up-to-date and compliant.
Step 7: Prevent Future Failures
Even after the equipment is operational again, there’s still more you can do to prevent future failures. Conduct a root cause analysis to uncover any maintenance gaps or usage patterns that may have contributed to the failure. MMI Hoist also offers preventive maintenance plans to help clients extend equipment life, reduce unplanned downtime, and avoid costly emergencies in the years to come.
Respond Quickly, Repair Confidently
Emergency hoist failures demand fast action and qualified expertise. MMI Hoist is well equipped to restore safe and reliable operations to your projects. Even when failures happen, the right process and service partner can help you manage emergencies, minimize downtime, and get back on track with confidence.
MMI Hoist can be your partner for emergency repairs and long-term maintenance. Contact us today to keep your equipment moving and your team protected.