On-Site Visit Reveals Underlying Issues with Conveyors

During one of our recent site visits, the team were asked to investigate a client’s vibratory conveyors, which were manufactured by a different company and had long-standing problems. The client used a third-party vibratory conveyor spare parts supplier to deal with recurrent issues. As the spare company lacked the technical expertise to establish the root cause, their only solution was to keep buying spares, which was expensive and treated but not solve the issue. From our site visit, we established the cause of the problem, which we fixed, dramatically reducing their spare part requirements.

Identifying the Core Problem

Careful inspection revealed that the conveyor system was overloaded with more products than it could handle. This overexertion was not due to a single factor, but rather a combination of two critical issues:

Incorrect Base Configuration: The bottom part of the conveyor was not designed for the current operational needs, placing more pressure on the conveyor.

Product Change: This change in the type of product being transported has also caused the load and operation of the conveyor to change.

These challenges compounded the original design of the conveyor system by overworking it and causing many breakdowns that required spare part replacements.

Specific Expert Analysis Results in Successful Solutions

Due to our team’s technical competency, these fundamental matters were rapidly spotted, and the problem was solved at its source rather than just replacing the worn-out parts, which was the usual practice. It also proved to be more economical in the long run.

Solutions for Long-Term Effectiveness

Instead of continuing the cycle of repetitive spare part purchases, we advised the client on the following next steps:

• Adapting the conveyor base to meet the current operating requirements.
• Changes in the methods of conveying the product from one process to another since introducing the new product type.
• Adherence to a specific maintenance schedule specific to the subsequently altered system.
• On-site training was required to increase the operator’s ability to recognise possible problems and prevent them from developing further.

 The Role of Expertise

This case highlights the importance of businesses’ access to specialised technical expertise when managing industrial equipment. While sourcing spare parts from third parties may address immediate issues, it fails to tackle root causes, often resulting in a cycle of repeated breakdowns and escalating costs. Our client broke free from this costly cycle by contacting us for our in-depth knowledge of conveyor systems. This proactive approach is expected not only to reduce downtime and maintenance expenses but also to extend the lifespan of their equipment significantly.

During our on-site visit, we demonstrated the value of a professional assessment of industrial facilities. By addressing the underlying causes of systemic issues, businesses can realise substantial gains in productivity, reliability, and cost-efficiency.