3 Days (5 Modules)
Objective: Consistent and improved maintenance practices.
The Basic Conveyor Maintenance Course consists of five modules, sequenced logically so that participants gain a basic grounding prior to getting involved with any advanced analysis. The overall objective of this course is not only to create a practical learning environment but also to create a consistent approach to the way maintenance is done on a materials handling system.
This course is conducted be a Gulf presenter who comes to your site prior to the commencement to familiarise them selves, or where possible, site- based personnel experienced in conveyor system maintenance can conduct the course with supplied learning materials.
The course materials consists of
- PowerPoint presentations
- A printed companion hand book covering all course contents
- End of session test questionnaires for assessment
- Introduction from site based safety personnel on general safety awareness. (This is a site specific process and may form part of an induction procedure)
- Module 1: Conveyor System Safety.
- General overview and detailed presentation
- Site inspection where the learning group is divided in two and, armed with digital cameras etc, assess the compliance or otherwise of particular aspects of the site as far as safety and safety hazards are concerned.
- Inspection report writing based on the groups site inspections
- Group presentation of report findings and group analysis.
- Recap on safety aspects covered in Day 1
- Presentation of main workshop material using modules 2 to 4
- Objectives; give all participants the confidence to look into the problems they may encounter; learning to approach issues with an open and enquiring mind so real causes of these problems can be found; create cultures 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.
Module specifics for Day 2:
- Module 2 – 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 module helps participants understand how a conveyor system should be looked at holistically where all components are inter-dependent, and not considered as a collection of individual components. This module encourages interaction and questions.
- Module 3 – 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 those observations to identify more accurately what is happening.
This is generally completed prior to lunch and is followed by a site inspection where the theory is tested against site observations.
- Module 4 – 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 key 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.
Following the presentation the group is split into two groups to conduct detailed conveyor inspections. Digital cameras etc are used to record issues that are identified so that a practical report can be produced. The reporting, and writing up of the reports completes Day 2.
- Recap on Day 2
- Module 5 – Reliability Improvement Processes. This module teaches the techniques and processes that can be used to continually improve the maintenance and performance of conveyor systems. 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 Basic Conveyor Maintenance course is concluded with the participants presenting their findings to a peer group. This creates necessary confidence within the group to apply the principles learnt as individuals going forward.