Conveyor systems are important pieces of equipment used in many industries. Whether you are a manufacturer, distributor, or retailer, maintaining your conveyor system is essential to running a successful business. Regular maintenance helps to ensure that your conveyor system runs smoothly and efficiently, saving you time and money in the long run. Knowing what to look for and how to address any issues that arise is key to keeping your conveyor system in top shape. In this article, we will discuss tips for conveyor maintenance, so you can keep your conveyor system running in peak condition.
What are common issues with conveyor systems?
Conveyor systems often experience wear and tear over time. While they are designed to last for many years, the frequency of use, the amount of weight they are designed to carry, and the overall condition of the system all play a role in how long they will last.
As a machine operator, you are also responsible for inspecting the conveyor system periodically. Depending on your industry and the type of conveyor system you have, you may not need to inspect the system as often as other operators. However, it is important to inspect the system periodically to make sure there are no issues or potential problems that need to be addressed immediately. Inspecting your conveyor system can also be a good way to spot any issues that need maintenance before they become larger problems.
What safety measures should be taken when performing conveyor maintenance?
Before you begin any maintenance work on a conveyor system, make sure you are familiar with the system and the potential hazards. For example, the system may include moving parts that could cause you injury if you are not careful. When working on older systems, you may also need to wear breathing equipment to protect you from harmful fumes. You should also be familiar with the location of any shutoff valves or emergency stop buttons to make sure you can stop the system if needed. If you are unsure about the proper procedures or safety precautions to take when working on a conveyor system, contact your supervisor or the person responsible for maintaining the system for instructions.
What should you look for when inspecting conveyor systems?
During your conveyor system inspection, you should look for problems with the system, such as wear and tear. You can also perform a preventive maintenance checklist, which is a good way to address certain issues before they become more serious. The ABCO Systems Maintenance and Service team uses checklists to ensure they address all aspects of your systems. You can find a checklist online and customize it to suit your system. There are also online tools available that allow you to enter information about your system and generate a checklist customized to your specific equipment. When performing your inspection, keep an eye out for any of the following issues: – Excessive noise – This could indicate a problem with the bearings or other system components. – Oil leaks – These can indicate wear or damage in the system. They can also pose a fire hazard if the oil drips near hot components. – Poor lubrication – This can cause friction and overheat the system. – Excessive vibration – This can be an indication that parts are loose and need to be replaced.
How often should you inspect the conveyor system?
Depending on your industry and the type of conveyor system you have, you may need to inspect the system regularly. Manufacturers will often provide recommendations for the best maintenance practices for your system. You should also follow the manufacturer’s recommended maintenance intervals to avoid costly breakdowns and repairs. If you do experience a breakdown, it is important to troubleshoot and repair the system as quickly as possible. A minor issue that goes unaddressed can become a major problem quickly. If you schedule regular inspections, you can spot potential issues before they become serious.
How can you prevent conveyor system breakdowns?
A regular maintenance schedule is essential to prolonging the life of your conveyor system and preventing breakdowns. Periodic inspections can help you identify wear and tear before it becomes a serious problem that requires extensive repairs. You should also make sure to use the system within the manufacturer’s guidelines. If you overload the conveyor system by exceeding the weight capacity or attempting to move more products through the system than it is designed for, you greatly increase the risk of breakdowns and other problems. You can also help to prevent breakdowns by following these tips: – Maintain proper speed, load, and tension settings. – Clean the system regularly to reduce the risk of corrosion and contamination. – Use lubricants to reduce friction in moving parts. – Replace worn or damaged parts promptly.
What should you do if you experience a breakdown?
If your conveyor system breaks down, you should first attempt to identify the cause of the issue. If you are not able to identify the problem, you may want to call a professional to help troubleshoot the issue. Some common issues and their causes include: – Excessive noise – A problem with the bearings, belts, pulleys, or other system components. – Oil leaks – Damage to seals, gaskets, or other system components that allow oil to leak. – Poor lubrication – Parts moving against each other without sufficient lubrication. – Excessive vibration – Worn or damaged parts that are loose and may cause excessive vibration. – Overloaded system – Exceeding the weight capacity or moving too many items through the conveyor system.
What are the benefits of regular maintenance?
Regular maintenance is essential to keeping your conveyor system in working order. Even if you have a brand-new system, regular maintenance will help prolong the life of the system. A well-maintained system will operate more smoothly, efficiently, and safely compared to systems that are neglected. You can also expect to see a reduction in breakdowns and repairs if you perform regular maintenance on your system. This can save you time and money in the long run. A well-maintained system will also be safer to operate, which is important when working with heavy machinery. A poorly maintained system can lead to accidents and injuries, which is why it is so important to follow best practices for conveyor maintenance.
What are the top conveyor maintenance services in New Jersey?
While you may be able to perform some of the maintenance work on your conveyor system yourself, you can ensure your equipment is always up and running by having a preventative maintenance contract in place. ABCO Systems can perform a regular inspection of the system, replace worn or damaged parts, apply lubrication as needed, adjust tension and speed settings, and perform any other regular maintenance tasks. It is important to choose a service that is certified and follows manufacturer recommendations when working on your equipment to help ensure they perform the work correctly.
Why choose ABCO Systems for your conveyor maintenance?
Conveyor maintenance is an important part of running an efficient business. ABCO Systems, LLC provides its customers with best-in-class installation of some of the most technologically advanced material handling products on the market. To be compliant with manufacturers’ requirements for warranty, the systems must be properly maintained as part of a comprehensive pre-scheduled maintenance program. Headed by Heather Castro as Service Department Manager, ABCO Systems technicians and service staff are highly qualified to perform these required services. If you want to keep your systems running, run with the WolfPack and ABCO Systems Maintenance and Service Team.
Preventive maintenance is a critical component of any maintenance strategy. It is a key factor in lowering maintenance costs, reducing equipment downtime, improving asset lifespan and efficiency, and increasing workplace safety. Having a clearly defined, well-thought-out maintenance plan is a crucial first step in long-term success.
Preventive maintenance is critical to any business looking to reduce maintenance costs and the number of reactive maintenance issues. But … what exactly is preventive maintenance?
Preventive maintenance involves taking the necessary precautions and actions to prevent accidents or equipment failures from occurring before they happen. Some examples of this would be: performing regular business and equipment inspections, cleaning and lubricating essential equipment, and tidying your business’s grounds are all examples of preventive maintenance.
The goal of preventive maintenance is to proactively prevent equipment failure and reduce the risk of accidents and downtime. Taking certain precautions to ensure minimal risk to your business ensures you and your staff can focus on organizational goals, instead of having to repair what is broken.
Any type of maintenance that is not reactive (i.e. a response to a problem, malfunctioning equipment, technology, etc.) is preventive, and there are many different types of preventive maintenance that pertain to different areas of a business, or specific timing.
In short, as a business owner or manager, you face a certain amount of risk when it comes to customer and employee safety, equipment operations and safety, and property upkeep, among other areas. Implementation of regular preventive maintenance measures can ensure your business is protected from substantial risks and accidents, keeping your business goals and safety goals intact.
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ABCO Systems sells used material handling equipment. In fact, ABCO Systems sells an awful lot of used material handling equipment. We have over an acre of outdoor secure storage conveniently located just outside of the NJSEA. We also have 30,000 feet of indoor storage space. Used material handling equipment is an integral part of our business and that is why we continue to keep such a large stock available at all times.
However, as the culture of logistics and distribution changes, I do wonder about the future of installing used systems. The logistics culture is evolving, and the validity of used systems appears to be changing along with it.
First and foremost, logistics professionals are realizing now more than ever, that distribution centers are not cost centers, as they were seen in the past, but rather they are a way to create long term cost savings. With the increasing cost of commercial/industrial space and the increasing minimum wage, one of the most obvious ways of saving money is to design an “optimized DC” that utilizes the cube, creates lasting efficiencies and has a logical and clean product flow.
Expectations have changed dramatically. Distribution and how quickly customers receive their purchased goods is the new race that is constantly being improved upon. Customers want their product in a timely manner. The speed and accuracy which is essential to moving a product through a DC is being realized as an essential part of todays evolving business model.
The interesting part about all of this though, is that it is just the beginning. The change in culture is all relatively recent. The shifts in the distribution model are all very recent. When you look at the changing landscape you can see that we are just starting to scratch the surface.
Because of these shifts, logistics professional are realizing that a truly optimized DC is going to be designed based on the business model of each and every distribution end-user. There are endless criteria that will be relevant to each business and their distribution requirements. The chances of finding a used material handling system that will save money over the long term based on true engineered solutions is slim.
Depending on what the end user is looking for, while slim, it is most certainly still possible. However, much of the shift is lending credibility to the fact that the majority of distribution centers do not have one single material handling solution. For example, pallet racking is extremely common in a DC. However, while in the past, pallet racking was often a one size fits all solution, most DC’s today are going to have pallet racking for their bulk storage and still require pick faces, along with conveyance, packing, staging etc. On top of that, the once simple pallet rack solution is getting more specific as well. Heights of buildings, along building column placement, along with weight capacity, along with shelf levels all have a part in how the DC will operate in both the short term and continue to save money in the long term. The days of finding the closest match, with the lowest cost, are ending. Adding a few more rows or racking, or another pallet level or even pick locations below the bulk storage can literally save tens of thousands of dollars over the years and create greater efficiencies.
Saving a few dollars by installing a used system could very well cost far more over time by not installing the “right” system. Used conveyance was very common in the past. Today, there are so many details that make a conveyor or sortation system applicable for an operation that finding a used solution almost guarantees that you are sacrificing something.
While we are talking about cost, there is also not that much of a savings. Typically, the only savings available comes from the actual equipment itself. Whether conveyor, pallet rack, or GOH, the engineering, the freight, the installation all costs the same. Specifically with conveyor or sortation, there is still the cost of the electrical work, the panel and the safety requirements. That still all costs the same.
So while there might be a savings in actual material, when you add up everything, it is a marginal savings at best. A used 8’ pallet rack shelf beam typically sells for approximately $15. A new 8’ pallet rack shelf beam costs approximately $19. A project with 5,000 pallet positions is likely going to cost around $300,000. The savings on the used beams is minimal.
On top of that, used material handling equipment comes with its own set of problems. Stickers, damages, rust, to name just a few. Specific to conveyor, it is a mechanical system and it is not typically possible to know the quality of the system you are getting, how well it was maintained and how much it will cost to make it work right again. The same way you wouldn’t want to buy a used car with no service history, buying a used conveyor comes with an awesome amount of uncertainty.
We won’t stop selling it because it is certainly still relevant in many applications. However, over the years, we have become much more of an engineering company that is building solutions that are tailored for each customer to save money over the long term. The right system will undoubtedly save money over the marginal savings of used equipment.
In addition, the distribution model is now clearly a part of the business. For many thriving businesses such as 3PL’s the distribution is the business. For manufacturers doing their own distribution the same philosophy applies. The material in the building is a showcase and helps create a better atmosphere for employees along with a better visual for potential customers. A look into any of the big distribution centers of today will show you a clean, well organized operation.
In conclusion, there are clearly applications where used material is still needed and will still save money. But as time goes by that need is going to continue being reduced. The model will continue to trend towards greater efficiency, space utilization, safety and an overall coordinated effort to provide better customer service.
ABCO Systems designs and installs distribution centers. Contact us for all of your warehouse needs.
Reactive Maintenance focuses on fixing equipment and bringing it back to its operating condition after it’s already broken. Emergency repairs such as this, cost 3-9 times more than planned repairs. This kind of approach is significantly more expensive because of unexpected shutdowns during production instead of pre-planned maintenance shut downs. Rush shipping for emergency parts cost much more than regular shipping and staff is often forced to work overtime to repair machinery.
Planned Maintenance
Planned maintenance reduces stoppage and the additional costs of emergency repairs. A scheduled plan gives you the opportunity to improve your operations and continue to operate at full speed.
Some Disadvantages of Reactive Maintenance
Shorter life expectancy of equipment – Reactive maintenance does not keep your equipment running in optimal condition. Over time, systems that have not been properly maintained wear and break faster and don’t maximize their initial investment.
Safety issues – When work is scheduled, technicians have time to review the procedures and safety requirements to complete the job correctly. Technicians tend to take more risks when maintenance work is reactive because they are under pressure to get equipment running without further time delays.
Time-consuming – Reactive repairs tend to take longer. Factors like time to diagnose, travel time, time to pull parts from stores or emergency order, and time to pull correct manuals and schematics, all impact how long it takes you to get back up and running.
Sporadic equipment downtime – Planned maintenance can be scheduled while unplanned repairs can happen anytime.
Interferes with planned work – Emergency repairs are usually prioritized at the expense of day to day work. Planned work may have to be delayed or cancelled entirely.
Collateral damage – A minor issue could quickly turn into a major repair without proper maintenance.
Indirect costs – Unplanned downtime can lead to schedule problems if equipment cannot be returned to production in time. This can damage your reputation with clients and cause revenue issues.
Repeat issues – Emergency repairs do the bare minimum to get the equipment up and running. This can lead to future issues and eventually cause more downtime.
Higher energy costs – When equipment is not properly maintained, it uses more energy. Doing simple things like greasing moving parts or changing filters can reduce energy consumption by up to 15%.
At ABCO Systems, we offer our clients a full maintenance plan that is designed to address any potential problems that could pop up at any time. When you sign up for this plan, you can expect the following:
Regularly-scheduled maintenance
On-site visits to inspect machinery
Real, low-cost resolutions for discovered issues in the system
Our qualified inspectors and technicians make it their responsibility to find failure points that could lead to future problems. A maintenance plan with our company is one of the best preventative steps that you can take.
Contact Us Today
If you’re ready to commit to keeping your systems up to par, contact ABCO Systems for the next step. We can be reached at 201-507-0999, or you can also fill out our online contact form.
