Understanding and predicting quay crane breakdowns using explainable AI

Quay cranes (QCs) play a vital role in ship-to-shore operations, enabling the seamless transfer of cargo between sea and land. However, increasing trade volumes require faster and more cost-effective container handling, exerting significant pressure on QCs and leading to greater wear on critical components such as wires, hoists, and rope clamps. While operations research has explored maintenance scheduling to improve terminal performance, comparatively little work has examined how machine learning can exploit the growing volume of QC monitoring and operational data to predict breakdowns before they occur. This study contributes to this area by integrating terminal operations data, QC monitoring logs, and meteorological observations into a unified analytical framework. We employ explainable artificial intelligence (XAI), using both global and local SHapley Additive exPlanations (SHAP) to identify the operational and environmental factors most strongly associated with QC failures and to illustrate concrete, instance-level examples of how specific conditions contribute towards breakdowns. In parallel, we develop a robust machine learning pipeline built around nested cross-validation to assess the predictive capability of multiple classifiers for forecasting QC breakdowns. Our XAI analysis reveals that breakdown risk is closely linked to QC working time, the distribution of moves across simultaneously operating QCs, hoist overload and trolley alignment warnings, and adverse weather conditions. Among the evaluated models, LightGBM achieved the highest predictive accuracy, reaching up to 83% in identifying breakdown-prone scenarios. These findings demonstrate the feasibility and value of data-driven predictive maintenance for QCs, providing insights that support safer, more reliable, and more efficient terminal operations.