PLANT MANAGEMENT
Incorporating failsafe automatic testing technology into metal
detection equipment can save time and labour resources
find themselves at a money pit tipping point. Modernise or stick with legacy equipment? Ask your
supplier to be upfront about replacement part costs. If they’re not prepared to provide these, that’s a big red flag. Realistically, a Fortress metal detector will probably require two replacement boards at most in its lifetime – most only one. To give a benchmark, Fortress’s board costs around £750. Also, ask to see data on machine failure rates. If these aren’t available, word of mouth business recommendations are also reliable. All Fortress machines are designed to be backward
ABOVE: Legacy metal
compatible. Te electronic boards are interchangeable, which means customers can hold just one spare in stock. Or they can simply swap a board out from another machine while waiting for a replacement to be delivered. For many manufacturers, downtime is a significant drain on profit. Every product that comes off the line after processing and inspection has value. If a production line is put to a halt, this seriously hinders a company’s ability to reach profitable production levels. Unplanned downtime in particular is the biggest dilemma. Although no value is being produced, operational overhead costs continue to grow, which directly impacts the bottom line. What’s one of the leading causes of this issue? Equipment failure. According to research conducted by OneServe in partnership with British manufacturers, unplanned downtime causes roughly 3% of all working days lost annually in manufacturing due to faulty machinery. Tis equates to 49 hours of work and £31,000 per company. What’s more, approximately 53% of machinery downtime is caused by hidden internal faults. For mass food manufacturers of all sizes, losses of this scale can rapidly make or break a business. Equipment that’s poorly maintained will likely breakdown more frequently. Tis impacts quality, as well as productivity and Overall Equipment Effectiveness (OEE). Adopting a ‘run to failure’ method is risky. Rather than reacting to emergency tasks, Fortress recommends customers perform an annual preventative maintenance check. Many global customers sign up to this service check. Additionally, carrying out relatively straightforward
detectors such as Fortress’ Stealth system, can run for 20+ years and be upgraded with the latest hardware and software
maintenance – such as regular visual checks on the conveyor and monitoring the lubrication levels – can
make a big difference to a system’s running costs. In the event of a breakdown, remote assistance and access to a 24/7 hotline can help to troubleshoot issues faster.
AVOIDING HUMAN ERRORS Equipment failure is, of course, just one part of the problem. Operator mistakes are the second largest cause of unplanned machine downtime. Stepping up training protocols doesn’t just teach production operators to recognise and repair their own equipment. It also shows them how to properly operate and calibrate the machinery, therefore cutting down on issues from happening in the first place. Quick learning features, multi-lingual control panels with shortcut keys and automatic calibration saves time and costs by avoiding false production starts. Regardless of how up-to-date food inspection systems are, human error and misuse can never be completely ruled out by machines. It’s essential that robust procedures and practices are in place and that staff members clearly understand their roles and responsibilities. Make good use of what training suppliers offer to build awareness of food safety risks and improve understanding of equipment among operatives. Automatic test technology – such as
Halo – can also save considerable time and labour resources. Rather than just performing manual checks (which honestly returns modest investment), Halo can slash the time during which a problem with a metal detector can go undetected. Tis can reduce the number of suspect products that must be discarded or recalled in case of an incident, saving more money in the process. Yes, it’s true; some may argue that legacy equipment has had its day. However, Fortress believes that, providing the base unit is in good working order, they can be updated with the very latest technology to optimise TCO.
As a testament to how robust these metal detectors are, one Fortress metal detector continued to live another day after being engulfed in a fire at a Canadian lumber unit. Another in Brazil was in good working order after being fully submerged in water.
Phil Brown is MD of Fortress Technology Europe.
www.fortresstechnology.com
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