The Maintenance Workshop consists of four (4) modules, sequenced logically so that participants gain a basic grounding prior to getting involved with any analysis. The course presenters come to site prior to the course to familiarise themselves with the site or need to be site based personnel experienced in conveyor system maintenance. The overall objective is not only to create a practical learning environment but also to create a consistent approach to the way maintenance is done on the materials handling system. It is aimed at giving all participants the confidence to look into the problems they may encounter in a material handling system. They will learn to approach issues with an open and enquiring mind so that they can find the real causes of these problems. We want to create a culture where maintenance problems are fixed the first time and fixed permanently rather than creating non-permanent solutions that need to be addressed time and time again. The contents of the modules that will be presented during the workshop are as follows: Module 1 – Conveyors and their Components This module works through all of the various components that make up a conveyor system and how they interact. It takes the time to explain the key functions of components and the importance of the inter-relationship between them. Through questions and answers, the course endeavours to help participants understand that a conveyor system should be looked at holistically, and not considered as a collection of individual components, as all components are inter-dependent. This module should encourage interaction and questions. Module 2 – Conveyor Inspections This module works through the key aspects of what is required to get the most out of a conveyor inspection. It will also detail techniques that will facilitate the inspection process plus help participants to interpret what they observe and use this to identify more accurately what is happening. This is completed prior to lunch and is followed by a site inspection where the theory is tested against site observations. Module 3 – Trouble Shooting (including belt tracking techniques) This module works through causes of common conveyor problems, and how to accurately identify the root cause. It spends quite a bit of time on belt tracking issues and in particular teaches very practical techniques on how to identify the cause of tracking problems. The use of Ishikawa (‘fishbone’) diagrams to conduct a root cause analysis is also addressed. This presentation immediately follows lunch. Following the presentation the group is split into two groups to conduct detailed conveyor inspections. Digital cameras are used to record issues that are identified so that a practice report can be produced. The reporting and writing up of the reports should complete Day 1. Module 4 – Reliability Improvement Processes This module is preceded by a re-cap of Day 1. This module teaches the techniques and processes that can be used to continually improve the maintenance and performance of the conveyor system. It brings together the emphasis on doing things correctly, focussing on root cause issues and eliminating or reducing maintenance where possible by focussing on reliability processes. This module finishes with an exercise based on what has been seen during the various site inspections. The process used to report the findings will be a “Failure Modes and Effect Analysis”. In the exercise, one key issue selected by the participants will be subjected to a detailed root cause analysis using an Ishikawa (or Apollo if the site prefers) diagram. The material is collated into a report with recommendations and is representative of what has been learned in the course. The course is concluded by the participants presenting their findings to a peer group. This is important as it is part of creating within the group the necessary confidence to apply the principles learnt as individuals going forward.