Potain doubles MCT 2205 output as Zhangjiagang factory ramps up

Manitowoc says lean manufacturing initiatives at its Zhangjiagang plant in China have lifted output significantly since 2018, when the company introduced its “Manitowoc Way” programme at the site. The factory builds Potain top-slewing tower cranes for emerging markets, and the manufacturer reports that during one recent ramp-up, production of the 80-tonne MCT 2205 doubled within three months.

The MCT 2205 has become a strong seller in the Middle East and Asia, and shorter lead times for the high-capacity model are the most visible customer benefit of the programme, according to the company.

More than 170 improvements on the shopfloor

Since 2018 the Zhangjiagang team has completed over 170 documented manufacturing improvements and recorded more than 2,000 best-practice examples. Recent gains include a 20 percent increase in laser tube-cutting for masts and jibs, while additional investment in robotic technology has improved full-penetration welding by 15 percent. Improved tracing of cranes through the key manufacturing stages is also credited with raising product quality.

“We introduced The Manitowoc Way to Zhangjiagang in 2018 and since then implemented a range of improvements while guaranteeing the product quality Potain customers expect. When we build tower cranes, our first focus is on safety in our plant, while we simultaneously work to improve manufacturing quality. Alongside this, we’re also working to make commissioning and maintenance simpler.”

— Brian Wang, senior vice president of emerging markets, Manitowoc

Capacity for growing demand

The capacity increase is aimed squarely at emerging markets, where demand for larger top-slewing cranes on infrastructure and high-rise work continues to grow. The MCT 2205 N80 built at the plant offers a maximum capacity of 80 tonnes and a jib of up to 85 m, with a 19.5-tonne jib-end load.

“Workplace safety, organization, employee-led problem-solving, and process optimization are part of our daily operations. We’re proud of our achievements and always honored to welcome customers to Zhangjiagang to see the advances for themselves,” Wang added.

Manitowoc says the site will continue to be developed as part of its wider push to shorten delivery times for tower cranes in the region.