MATERIALS & HANDLING U
nscheduled downtime of belt conveyors in bulk handling operations can be calculated in cost per
minute. For sanity’s sake, operators should not calculate this.
It’s likely
to reveal the severe logistical and scheduling ineff iciency of service contractors and equipment manufacturers as well as seriously raising the respective operator’s blood pressure. Generally, when operators install
retrofi tted conveyor solutions, they focus on the up-front price with little consideration for the cost of ongoing service, maintenance costs, and supply chain. But down the road, when critical service or parts are needed, the cost per minute diff erence between days and weeks of downtime or keeping the system limping along at 25-50% production can amount to an entirely new equipment retrofi t. Research published by the
Australian Coal Association indicates the cost of downtime is in the order of fi ve times (5x) the cost of replacing the component. When the root cause of downtime is related to the basic conveyor design, the downtime cost is approximately two times (2x) the cost of the redesign.[1] At fi rst, these ratios may seem to
be erroneous or even backward but consider that a component failure often involves maintenance with a relatively short downtime window for replacement, whereas a basic design mistake often involves a signifi cant capital expense and a prolonged outage for correction. This is why having a close
relationship with equipment manufacturers and/or their certifi ed contractors that off er responsive ‘factory direct’ products and services is important to the cost of operation. The main factors to consider are service availability, technical expertise/safety, and supply-chain logistics.
SERVICE AVAILABILITY The mystery of the ‘disappearing manufacturer’s representative after installation’ is an old one. However, reliable and timely site visits are a hallmark of a solid partnership between the operator and the factory-direct manufacturer. Service technicians and certifi ed
www.engineerlive.com 35
Trucks specially equipped with the necessary tools and parts arrive to offer service and solutions
representatives who are available during problem-free uptime are likely to be responsive during panic- inducing unscheduled downtime. Site visits are also not arbitrary.
A reputable equipment manufacturer representative will examine not just their components but the entire conveyor system, off ering preventative maintenance support. The goal is to fi nd indicators of the causes of
downtime and off er practical and timely solutions. For example, Martin’s Walk the Belt program is specifi cally designed for predictive maintenance. A Martin Service Technician (MST) or certifi ed contractor will physically examine the entire system with an extensive checklist and then write a report, often with photos, observations, recommendations, and solutions to improve safety and eff iciency.
Walk the Belt checklists are accompanied by tests, results, and solutions to improve conveyor performance
All images Copyright © 2025 Martin Engineering
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44
