Skilled Personnel for Safety and Reliability
It is crucial that only competent, well-trained personnel, equipped with proper test equipment and tools, perform conveyor maintenance. For the sake of safety and efficiency, these maintenance personnel should be experienced employees with the authority to shut down a conveyor for minor repairs that prevent major outages or equipment expenses.
As maintenance crews are reduced and the demands on conveyor systems increase, maximizing the efficiency of available personnel becomes essential. One effective approach is to document procedures for performing tasks safely and efficiently, specifying the necessary tools and equipment. This documentation not only enhances current operations but also aids in training new employees as experienced personnel retire or move on. 
Implementing a computerized maintenance-management system (CMMS) is particularly beneficial for housing maintenance and repair procedures, managing work orders, and prioritizing tasks. Such systems also track maintenance costs for specific equipment, crucial for justifying upgrades or new purchases.
A maintenance program structured around these procedures proves significantly more efficient and reliable in the long term.
Contract Services
With many plants reducing employee numbers, numerous companies now rely on outside contractors for conveyor equipment installation and maintenance. This strategic use of contractors allows plant personnel to focus on core operational activities. Contractors in the bulk-materials handling industry generally fall into two categories: general and specialty/niche. Each type offers distinct advantages, provided their limitations are understood. General contractors undertake a wide range of tasks but may lack deep expertise in all aspects of conveyor systems.
In contrast, specialty/niche contractors specialize in specific components or areas. Often trained and certified by manufacturers, they possess the necessary skills to install or maintain equipment more effectively than general contractors. Specialty/niche contractors typically offer performance guarantees on labor and the components they supply.
Outsourcing spillage cleanup is another way external contractors can benefit plant operations by freeing up personnel. Additionally, contracted spillage cleanup can help identify root causes of spills, potentially justifying upgrades or replacements to existing systems through procedural changes.
Inspection Strategies
Routine maintenance inspections can significantly extend the life of conveyor belts and components while enhancing overall performance by addressing minor issues before they escalate into costly problems. In top-notch operations, maintenance personnel regularly conduct detailed inspections of the conveyor system to preempt potential issues. It's crucial that these "conveyor walkers" are unencumbered to ensure safety and efficiency during their inspection rounds.
Essential equipment includes:
- Flashlight: If the conveyor inspector will be looking into closed chutes or underground areas such as chutes and reclaim tunnels
- Means to record information: Ranging from a pad of paper on a clipboard to a hand-held computer
- Personal Protective Equipment (PPE): Hard hat, safety glasses, hearing protection, and respirator as appropriate to plant conditions
- Radio or cell phone: To allow communication to the control room or maintenance office
Seeking an outside perspective can often highlight areas that plant staff might overlook as routine. Some suppliers or manufacturers offer to inspect the entire system and provide a comprehensive status report. The most effective method to identify and troubleshoot conveyor system problems is by observing it in operation. While no repairs should be attempted during operation, observing the system's performance and listening to its sounds helps maintenance personnel pinpoint components needing repair or replacement.
Conducting a thorough belt inspection is challenging when the belt operates faster than 1.0 meters per second (200 ft/min). At higher speeds, significant damage may be visible, but smaller defects can easily go unnoticed. One effective solution involves walking the entire length of a stopped belt and inspecting it section by section. Alternatively, some conveyors are equipped with a slow-speed inspection drive, often referred to as a "creep" drive, operating at 0.1 to 0.25 meters per second (20 to 50 ft/min), facilitating detailed inspections at reduced speeds.