Page 19 - MetalForming July/August 2009

facilities and a challenge for
many older plants. For exam-
ple, one major manufacturer
(let’s call it Manufacturer A) designed and installed an extremely long main conveyor
with a good layout for opera-
tions but a poor layout for maintenance. More than 1000 ft.
long, the conveyor runs the
entire length of the plant, but
the trench in which it sits provides less than 24 in. of clearance on each side.
The plant diligently performed its housekeeping chores and kept the trench clean and clear of material. How- ever, eventually it decided to turn housekeeping responsibilities over to an outside service, whose employees lacked the plant personnel’s under- standing of the importance of keeping the conveyor trench tidy—to them it was just another hole in the floor. Over time the trench filled with debris. Along with hindering efficient operation, the debris blocked inspection of the lower
rails. As the rails finally wore out, the return strand of belt fell through the frame and became jammed. The press operator, thinking the conveyor was overloaded, continued to increase its speed and eventually caused a cata- strophic conveyor failure. It took the plant three weeks to clear away the debris and repair the conveyor.
There Must be a Better Way
Conversely, consider Manufacturer B, a company that designed its stamping and scrap-handling systems with main- tenance accessibility in mind, and now
In many metalforming facilities, press lines are interlocked to a main scrap conveyor, and if that main conveyor goes down the press lines automatically shut down as well.
follows up with a program of complete inspection and lubrication of the main conveyor every six
months. After more than 20 years of operating 24/7, its 800-ft.-long main conveyor still runs with the original belt, requiring only minor replacement belting sections, all due to the compa- ny’s robust maintenance program.
Whether or not you have the luxury of a fresh design, Manufacturer B’s course—regular and thorough inspec- tion and maintenance—obviously is the way to go. Sure, conveyor manufac- turers build their equipment to be tough, but let’s be realistic. These are mechanical systems subjected to high stress loads, extended duty cycles and
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