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BREAKING NEWS
Stimulus Tax Breaks Set to Expire
The clock is ticking on the tax breaks doled out as
part of the Economic Stimulus Act of 2008. Some
suggest that now is not the best time for businesses
to make purchases, but these tax breaks could save
businesses a significant amount of money. Some of
the available tax breaks include a write-off of up
to $250,000 on any equipment purchased this year,
more than twice the previous amount. To read a more
detailed explanation of these tax breaks and how to
take advantage of them, visit our website at
www.nelsonequipment.com
MAINTENANCE NEWS
12
costly conveyor maintenance mistakes
By Thomas E. Betts
Even though they depend on them, organizations don’t
give much thought to their conveyor systems until
there’s a breakdown. Then, a conveyor becomes a
major issue—production stops, employees are idle,
shipments are late, their customers are upset and
the company’s credibility is undermined. Here are 12
of the most common material handling system
maintenance mistakes and how to help avoid them:
Lack of regular inspections —
In most manufacturing operations, production
equipment receives the attention, but the products
are what’s important in a distribution center. A
conveyor system, no matter how basic or complex, is
an “invisible” link in
the total process. Making regular inspections of
your equipment helps employees better understand the
equipment they are using and makes them more apt to
take ownership of its care.
Missing maintenance records —
Encourage your organization to keep a maintenance
log on or near their
system with information on what maintenance has been
performed and the
date, along with anything that should be watched.
This can be particularly useful in facilities where
there are several shifts. It’s also helpful if there
is a change in personnel. Most importantly, it helps
document the history of the equipment.
Engineered Systems Failing to take the temperature
of motors and reducers —
While motors may not have a fever, they can
overheat. A temperature spike indicates that
something is causing an overload. Having to replace
a burned-out motor during a production period means
downtime, particularly since most facilities don’t
have a backup supply.
Not adhering to OSHA standards —
Many organizations view a safe workplace as an
expression of their values and a commitment to their
employees and customers. Yet, because
of the constant pressure in a production
environment, they may be tempted to neglect
equipment safety. Injuries are costly in time lost,
the need to replace an employee and Workers’
Compensation expense. In many cases, investigation
reveals that the cause of injuries is the direct
result of missing safety equipment. Make sure you
know what steps should be taken and how you can help
accomplish them.
Lack of adequate maintenance coverage —
To reduce overhead expenses, organizations often
have few maintenance
personnel in their facilities. Then, when a
maintenance person goes
on vacation, there may be little or no coverage at
all. A cost-effective solution is having an
experienced and certified conveyor service person
make periodic inspections and be available when
in-house coverage isn’t available. This will serve
as the back up support needed, and keep the
organizations overhead expenses to a minimum without
sacrificing necessary support.
Inadequate parts inventory —
As many folks often learn too late, certain parts
may not be readily available when there’s a
breakdown. It’s not appropriate to inventory every
part, but there are certain key components such as
motors, couplings for line shafts, bearings and
photo eyes that should be kept on hand. Survey your
conveyor system and draw up a list of key components
needed, including part numbers.
Not learning from repeated breakdowns —
In a distribution center, an ongoing pattern of
breakdowns is a message that something is wrong.
But, again, production demands often force
users to perform quick fixes to get the line moving.
Repeated fixes, however, should be an alert that
there is a larger problem that needs to be
investigated and resolved. Failing to do this will
only result in more downtime incidents, additional
costs coupled to this lack of productivity. Making
sure everyone realizes the importance of proper
repairs is key to keeping a conveyor system up,
running and everyone happy.
Letting the little things slide —
Similarly, it’s critical for management in an
organization to know how
costly repairs can be if small problems aren’t
addressed quickly. For example, a photo-electric eye
goes out and they grab one from another
location to keep the line moving. Then there are
air line leaks, and everyone wonders why the
conveyor system is not accumulating properly.
Nothing is done about it, and everyone adjusts to a
now inefficient and dysfunctional operation.
Failing to care for the controls —
Ignoring maintenance of controls can be disastrous.
For example, switching scanners without recognizing
that each one is programmed for a particular divert
can create chaos. Also, lightning strikes can knock
out a control’s programming, the result of not
having proper surge protection. Again, more downtime
and costly emergency repairs.
Using a conveyor in ways it wasn’t intended —
In warehouses this happens often. A need arises and a conveyor
system is pressed into service without consideration
of its capabilities. One of the most common
examples is placing larger, heavier cartons on a
narrow conveyor. When this happens, there is stress
and wear on the entire conveyor, which will
eventually result in a breakdown. Then, there are those times when changes are made to an air line that affect the
slug release and the entire system fails to function
properly.
Avoiding those difficult places —
Wherever there is equipment, there are difficult places to get to,
sometimes up high, around in back and most of the
time too little room to maneuver. These are the breeding ground for expensive repairs and operational
issues. It’s these places that are rarely
(sometimes, if ever) lubricated. This is where you
find loose chains and sprocket set screws, causing
extra strain on the system and creating an emergency
waiting to happen.
Failing to train employees in conveyor operation —
One of the major causes of unnecessary maintenance costs occurs
when an end user fails to train its conveyor
operators properly. It is crucial that you impress
the importance of proper training. Then well trained
employees can become the eyes and ears for alerting
supervisors to potential problems. By knowing how
conveyors operate, how to avoid their misuse and how to spot maintenance issues, employees become the
first line of defense for minimizing problems and
reducing costs. While some may see it as “only a
conveyor,” others recognize it as a critical link in
meeting deadlines, getting orders filled and
reducing overhead costs.
NECI can assist you in developing a sound conveyor
maintenance program either in-house or by providing
this service for your company. For more information
on our programs and support, contact Kurt Nelson at
800.523.6199 or email him at
knelson@nelsonequipment.com. |
