Sustainable Modernization of Overhead Crane with Automation System PSS 4000 from Pilz
March 30, 2026
Safety upgrade for overhead cranes
Crane retrofit during non-stop operation
Overhead or bridge cranes are an integral part of the production and logistics chain at automotive supplier Marelli Mako Elektrik Sanayi ve Ticaret A.Ş. in the Turkish city of Bursa: the demands on their reliability are high, as the loads suspended overhead must not pose any danger to the operating personnel. When retrofits became due in 2024, Marelli Mako included safety aspects on its to-do list, in addition to optimising productivity and reliability. The aim was to perform the retrofit without interrupting the production process, if possible. Marelli Mako commissioned Pilz: today, the first of several cranes has been brought up to current standards. And that’s been achieved without restricting operational processes for any longer than necessary. At the heart of the solution is the automation system PSS 4000.
Today: Everything safe from the top down!
The initial situation: although the crane was safe to operate, it was not state of the art in all respects. This included the safety technology installed on the cranes. The key approach for Marelli Mako: Pilz was able to implement all modernisation measures without lowering the crane, i.e. in parallel with ongoing operations. In addition to conceptual advice on potential systems, the Pilz service package also included the replacement and modernisation of the safety technology, including engineering services. This is a future-proof automation solution for Marelli Mako. At its heart is the PSS 4000 automation system, which now includes an overload control system and safety speed monitoring of the hook drive. The Pilz operator terminal Pilz Human Machine Interface (PMI) was also integrated so that loads could be monitored in real-time. This safety architecture is designed to be internationally compliant – ensuring that everything is safe from the top down.
Benefits at a glance
- No production downtime, as the crane was retrofitted in parallel with ongoing operations
- Less time required for modernization: no need to lower the crane
- After retrofit: modern fault diagnostics reduce crane downtimes
Customer statement
“Throughout the entire project phase, Pilz confirmed our trust in them with a supportive and solution-orientated approach. We worked very well together to implement innovative solutions and overcome critical issues, and will continue to do so in future.”Muhammet Ali İÇİN, OHS (Occupational Health and Safety) Specialist at Marelli Mako (secornd from the right)
About Marelli Mako
Marelli Mako was founded in 1970 in Bursa under the name Mako Elektrik Sanayi ve Ticaret A.Ş. Two years later, the company began to produce starters, alternators and distributors. In the years that followed, heating and ignition coils were added to the portfolio, followed by lighting and ventilation systems in 1993. In 2005, the company became part of the Magneti Marelli Group. After the merger with Calsonic Kansei in 2019, it continued its business activities under the Marelli umbrella brand. Today, the automotive supplier operates under the name Marelli Mako Elektrik Sanayi ve Ticaret A.Ş. and is one of the largest automotive suppliers in Turkey.
Pilz’s products in the application
The automation system PSS 4000
The PSS 4000 automation system stands for optimum interaction between hardware and software components, network devices, and real-time Ethernet.
Machinery safety at each stage
Pilz can provide support throughout the whole machine lifecycle with their safety services for the design phase, operation, or retrofit of plant and machinery.
Related Story
Automation System PSS 4000 at W.E.B AG
At the Lower Austrian energy generator WEB Windenergie AG, the charging stations at the demonstration parking charging system were to be operated with direct current (DC). Added value: making it faster to charge electric cars. The aim was to make this as flexible as possible via a large number of delivery points, i.e. charging stations. However, as direct current poses greater safety risks than conventional charging via alternating current (AC), there was a requirement to implement the parking system and charging stations safely and efficiently for all concerned.
WEB Windenergie found a competent partner in Pilz: the central control instance in the demo plant, the automation system PSS 4000, ensures the necessary safety.
