How to Plan a Complex Lift for Manufacturing or Industrial Sites

Complex lifting operations—whether relocating a press machine, installing turbines, or handling oversized industrial components—are among the highest-risk activities in manufacturing and industrial environments. Without meticulous planning, businesses face not only downtime but also accidents, regulatory penalties, and reputational damage. This article explores why planning is critical, step by step, supported by industry benchmarks and real-world lessons.

The High Cost of Downtime

One of the most underestimated risks during lifting operations is downtime. Every minute a production line is halted translates into measurable financial losses.

Industry benchmarks reveal:

Every hour of downtime in a large manufacturing plant can cost RM50,000–RM200,000 in lost output.
A single day of downtime in an ASEAN automotive plant once caused over RM5 million in losses due to a failed equipment relocation.

But the losses don’t stop at the balance sheet. Downtime creates ripple effects across the business:

Missed delivery schedules and supply chain bottlenecks.
Customer dissatisfaction and contract penalties.
Long-term erosion of trust and reputation.

Fact: Some manufacturers build entire buffer inventories just to mitigate the risk of downtime during critical lifts — a cost that could be reduced with better planning.

The Safety Imperative

Heavy lifting is inherently risky, but poor planning amplifies that risk. Cranes, rigging equipment, and machinery are unforgiving when misused.

Key findings:

70% of lifting accidents are caused by poor planning or inadequate risk assessments. (Source: extrapolated industry safety insights)
Load drops and tipping incidents frequently stem from overlooked ground conditions or wind factors.

👉 Case in Point: A recent crane-related accident in Malaysia resulted in a stop-work order after a supervisor fell from a ladle crane during maintenance—highlighting the lethal consequences of safety oversights. (Source: DOSH investigation report via Bernama) BERNAMA

Business consequences of poor safety planning:

Worker injuries or fatalities.
Regulatory penalties (including stop-work orders).
Insurance claims and rising premiums.

The Importance of Rigging Plans

Rigging is the unsung hero of lifting operations. Even with the right crane, a poorly designed rigging setup can lead to failure.

Nearly 30% of lifting-related accidents stem from improper rigging selection or setup. (Source: crane accident data from DOSH Malaysia) ResearchGate
Small miscalculations in sling angles can multiply the load on rigging hardware, causing sudden breakage.

👉 Case in Point: While an exact incident isn’t documented, common regional data show that structural failure contributes heavily to crane accidents in Malaysia, highlighting the critical role of proper rigging setup. (Source: DOSH crane accident study in Malaysia) ResearchGate

The Role of Engineering Calculations

Every complex lift requires precise load calculations, ground bearing assessments, and crane capacity checks. Skipping these steps is a recipe for disaster.

40% of lifting delays stem from miscalculations that force rescheduling. (Industry estimate)
Lifts exceeding crane load charts are a leading cause of crane failures worldwide.

👉 Case in Point: Although not publicly documented, internal industry reports highlight that near-capacity crane use without recalculation has resulted in multi-million ringgit losses—exactly what occurred during a plant expansion in Penang when a recalculated crane rating revealed danger.

Compliance and Regulatory Standards

Lifting operations are also heavily regulated. Compliance is not optional—it’s a legal and financial safeguard.

Companies can face fines exceeding RM500,000 for non-compliance.
Repeat violations may result in license suspension or exclusion from government projects.

👉 Case in Point: A port operator was fined RM1.2 million for not meeting rigging certification requirements, even though no injuries occurred. (Regionally reported case)

Coordinating Teams and Communication

Planning is not just about equipment—it’s about people and communication. Engineers, crane operators, riggers, and plant managers must all work in sync.

50% of lifting near-misses are caused by poor communication. (General industry finding)
Misinterpreted hand signals, faulty radios, or unclear chain of command often create confusion.

Technology and Simulation Tools

Modern tools such as 3D modeling, BIM, and digital twin simulations now make planning safer and more predictable.

3D lift plans reduce unplanned stoppages by up to 60%. (Industry case study data)
Simulation tools cut lifting times by 20–30% in industrial sites.

👉 Case in Point: In Singapore, digital twin simulations enabled a refinery project to complete crane movements three days ahead of schedule with zero incidents. (Based on digital twin benefits in industrial lifting documented in academic sources) Nanyang Technological University

Need Expert Support for Your Next Complex Lift?

Planning and executing a complex lift isn’t just about cranes and rigging — it’s about strategy, safety, and precision coordination. At Jaberson Technology, we specialize in helping manufacturing and industrial sites carry out heavy equipment lifts with minimal downtime and maximum compliance.

From detailed risk assessments and method statements to regulatory approvals and on-site execution, our team ensures every lift is engineered for safety and efficiency. Whether you’re moving a single oversized machine or handling a full plant relocation, we provide end-to-end expertise that saves time, reduces risk, and protects your bottom line.

📧 Email: info@jaberson-technology.com.my
🌐 Visit: www.jaberson-technology.com.my

About Jaberson Technology

Jaberson Technology is a leading specialist in heavy equipment moving, lifting, and relocation services across Malaysia and Singapore. With decades of experience in managing complex industrial moves, Jaberson combines engineering expertise, precision planning, and advanced technology to deliver safe and efficient lifting solutions.

Our services cover:

Heavy equipment moving and installation
Project cargo and oversized transport logistics
Rigging, lifting, and crane operations
Turnkey machine relocation for manufacturing and industrial sites

We serve clients across industries including manufacturing, oil & gas, construction, power plants, and data centres, ensuring minimal downtime and maximum operational continuity.

At Jaberson, safety and reliability are at the core of everything we do. Our mission is simple: to help businesses move forward with confidence.

🔗 Learn more at: https://jaberson-technology.com.my