What are the best practices for using conveyors in material handling?

The conveyor selection can be crucial to determine a succesful system, it can be just a transportation module or to add value to drive, to take care products and to enhance the overall productivity.

In the realm of manufacturing engineering, conveyors play a pivotal role in material handling, enhancing efficiency and safety. However, the potential for mishaps, ranging from jams and spills to injuries, necessitates adherence to best practices. Firstly, regular maintenance and inspection are key to ensure longevity and optimal function. It's crucial to choose the right conveyor type and size based on material properties and process requirements. Proper training for operators ensures safe and effective usage, while guarding mechanisms can prevent accidents. Additionally, optimizing conveyor speed and load can help in preventing wear and tear. Implementing an emergency stop system and clear signage aids in handling unexpected issues.

Any conveyor system has three basic functions in package handling: 1) to move; 2) to accumulate; 3) to transfer. To solve a customer's problems we merely combine these functions in various ways to accomplish a particular result. To design a satisfactory, trouble free system, we must have some control over items being handled on the conveyor. We control the speed and direction and other actions by using belts for braking and metering as well as numerous mechanical devices. Again to simplify our approach, we can state that controlling any item involves three basic steps: sensing, comparing and effecting. You can readily see how we can increase the sophistication and complexity depending on the end results required.

Well, i have started my carrier through Material Handling Equipment Company. Elevator and Conveyor are subjective in modern era of manufacturing. Mining Industries requires the highest conveying system to handle shape, size and weight to transport goods to limit trucking inbound and outbound. Second most requirements of conveyors are at public transports viz airports, bus ports, railway stations etc. Where in minimum time, the luggage should be made to their respective passengers. Thus, conveyor system can bridge the work efficiency in all transit of goods from its manufacturing process to its logistic. There are various types of Conveyors - Belt, Chain, Roller, Pneumatic, Screw etc. to name the few.

A nuanced consideration of conveyors is crucial. Selecting the appropriate conveyor type is vital for efficiently designing the production space. In collaboration with our partners, we typically not only consider material properties but also take into account space utilization, layout efficiency, and ergonomics. The integration of automation enables the flexibility of conveyor systems to adapt to changing requirements. Traditionally perceived as inflexible, conveyors can enhance their flexibility through modular solutions. This approach promotes efficiency in factory planning, creating a modern, adaptive production environment.

In the conveyor system, for optimum performance, it should be inspected at regular intervals. Proper lubrication, adjustment, and replacement of wear parts are required. Timely inspection and maintenance will help prevent severe damages and enhance the life of the conveyor system and its components. Taking a simple belt conveyor as an example, it requires belt tension adjustment at certain intervals. Failing to do so can lead to the misalignment of the belt, resulting in spillage and damage to the belt edges or the belt itself, which represents a capital cost for the belt conveyor. What do u think ?

Regular maintenance and inspection of conveyors are paramount for their optimal operation and safety. This involves examining the state and alignment of integral parts like belts, rollers, and chains. Also, ensure that components are well-lubricated and have the right tension. Addressing worn or loose parts promptly can prevent unforeseen breakdowns or hazards. Always adhere to the manufacturer's guidelines and any relevant industry standards during these checks. By being proactive and systematic in conveyor maintenance, you not only enhance its lifespan but also ensure a safer and more efficient production environment.

Inspections are vital in the daily performance of equipment from a production standpoint and also a safety perspective. Identifying equipment that needs attention/maintenance and getting it places on the schedule for repairs and/or modifications.

Best practices for using conveyors in materials handling include regular maintenance, comprehensive training for operators, clear communication protocols, safety measures like guards and emergency stops, proper loading to prevent overloading, monitoring systems for early issue detection, routine inspections, maintaining a spare parts inventory, ensuring material compatibility, and optimizing energy efficiency. Implementing these practices promotes safe, efficient, and reliable conveyor operation.

Regular maintenance and inspection are pivotal for the seamless operation and safety of conveyors. This involves scrutinizing belts, rollers, chains, or screws for condition and alignment, ensuring proper lubrication and tension of components. Prompt replacement or repair of worn, damaged, or loose parts is essential to prevent malfunctions or accidents. Adhering to manufacturer guidelines, recommendations, and relevant standards during maintenance and inspection is paramount. This electrical precision not only sustains conveyor functionality but also aligns with safety protocols, ensuring the longevity and reliability of the material handling system.

The conveyor system is a simple machine but also hazardous. Care is needed, especially during operation. While most belt conveyors are open, there are various standards related to conveyor safety that are not followed across industries. O&M personnel should receive training on system operations and the associated risks. Proper induction in the field should be provided to them, covering safety features and interlocks for human and equipment safety. They should also have a clear understanding of DOs and DON'Ts. Safety should be ingrained in the organizational culture, driven from the top down. What do you think?

Ensuring the safety of workers around conveyors is crucial. Conveyors can present hazards like entanglement, pinching, or even severe injuries. To mitigate these risks, workers should receive comprehensive training on correct conveyor operation, emergency protocols, and awareness of potential dangers. It's essential for workers to wear suitable personal protective equipment, including gloves, safety goggles, and helmets. Strict adherence to safety guidelines and signage is also a must. Workers should maintain a safe distance from conveyor machinery, never attempt to touch moving parts, and promptly report any anomalies or accidents. This proactive approach can significantly reduce potential injuries and ensure a safer working environment.

Training related to conveyors is just as importance as their design. Giving employees the knowledge on how the equipment is designed to operate, how to maintain it safely, and allowing them the time to learn the equipment and understand it better promotes efficiency and safety.

Ensuring worker safety around conveyors is paramount. Training is a cornerstone, encompassing proper conveyor use, operation, and emergency procedures, alongside awareness of potential risks and preventive measures. Equipping workers with the knowledge to maintain a safe distance, avoid entanglement, and recognize safety signs is crucial. Personal protective equipment (PPE) plays a vital role, including gloves, goggles, or helmets. Workers should adhere to safety rules, keeping hands, feet, and clothing away from moving parts. Encouraging a proactive reporting culture for issues or incidents contributes to a comprehensive approach, emphasizing the importance of safeguarding workers in material handling operations.

Any moving parts pose danger to anyone working close to the parts. When selecting the right systems, ensure that moving parts are not exposed, especially when there are large volume of parts being moved by the conveyors. It does not always mean that expensive systems are safe. Do an assessment together with your workers who may be able to share more insights than what we can see as external parties.

The efficiency of a conveyor system greatly depends on its design and layout. An optimal design minimizes material travel distance and time, reduces the need for transfers, and avoids unnecessary bends or curves, thereby preventing potential bottlenecks or damage. It's crucial to design the system considering the available space, anticipated material flow volume and frequency, and seamless integration with other machinery. Furthermore, considering ergonomics ensures that workers can interact with the system comfortably and safely. A thoughtful conveyor design not only enhances productivity but also ensures smooth operations and minimizes wear and tear on the equipment.

Reduce waste or unnecessary movement leads to productivity improvement. Reducing the process flow means lesser distance travelled and lesser moving parts to take care of. It pays to look into waste and reduce as we learn more.

The layout and construction of a conveyor system significantly influence its efficiency in material handling. A well-designed system minimizes material transfer time, distance, and potential damage, while a poorly designed one can cause delays, waste, and damage. Optimizing layout and design is crucial, considering factors like space, material flow volume, frequency, machinery compatibility, and personnel ergonomics. Strategic consideration ensures a streamlined, productive material handling process, preventing disruptions and inefficiencies.

Layout design is a must and sometime not taken in duty consideration: of course productivity matters, but ergonomics, maintenance operations and safety bring a lot of value to companies. A multi-disciplinary approach to layout design can open to unexpected results.

El monitoreo de los conveyors en forma automática es necesario para evitar pérdidas, tales como tiempo muerto, defectos en los productos, fallas es equipos previos o posteriores. Igualmente la sincronía es un punto crítico sobre todo el sistemas muy sensibles debido a que los desfaces definitivamente van a crear un problema, este tipo de problemas son los más riesgosos cuando el desface es mínimo. Estos desfaces tienden a ser por falta de mantenimiento, desgaste en las partes involucradas o inclusive por una integración poco cuidada.

Continuous observation and management of conveyor operations are crucial for ensuring efficiency and safety in material handling. By utilizing tools like sensors, alarms, and software, one can monitor vital conveyor parameters like speed, load, and temperature. This real-time data can be instrumental in making operational adjustments, optimizing performance, and pinpointing issues. Furthermore, having controls like switches and remote devices allows operators to manage conveyor functions, making immediate alterations when necessary or activating safety measures. This proactive approach not only boosts productivity but also reduces potential hazards, ensuring smoother and safer operations.

A good design should bring to less automation, so more roboust and safe results. Sometime sensors are overused to overcome any potential issue, but reliability and safety are granted moslty using a short chain effects. Of course, if the conveyor is design to be a multifunctional system (transport, sorting, checking, tracing, etc.) then automation may create a powerful platform.

When selecting a conveyor system, consider the type of materials being transported, the weight and volume of materials, the desired throughput rate, and the distance to be traveled. Additionally, evaluate the available space and budget to determine the most feasible solution. Once a conveyor system has been selected, carefully design the layout to optimize material flow and minimize safety hazards. Ensure that there is adequate space for operators to work safely and that all conveyor components are properly guarded. To prevent downtime and costly repairs, implement a preventive maintenance program that includes regular inspections and lubrication of all conveyor components. Also, train operators to identify and report any problem.

Monitoring and controlling the conveyor operation can help to detect and correct any problems or deviations that may occur during material handling. Monitoring and controlling can involve using sensors, indicators, alarms, or software to measure and display the parameters and performance of the conveyors, such as the speed, load, temperature, or pressure. These data can help to adjust and optimize the conveyor operation, as well as to identify and troubleshoot any issues or errors. Monitoring and controlling can also involve using switches, buttons, or remote controls to start, stop, or change the direction or mode of the conveyors, as well as to activate or deactivate the safety features or emergency stops.

Energy Efficiency: Opt for energy-efficient motors and consider automated systems to reduce manual intervention and improve overall efficiency.

Back in 2006 I decided to pause my career in the Defense Industry and accepted a position with DHL as a Hub Floor Supervisor in the Northeast Region of the country. We processed around 350,000 packages in a 7 hour period. 200 inbound trucks and 200 outbound trucks. The hub was 75% automated. The automation system was created by Siemens. The system could handle somewhere around 100,000 packages an hour however the human element prevented full capacity. A package would get loaded on a conveyor belt from the back of the truck and sent through scanners, sensors, and cameras and dropped down the outbound conveyor. The issue was the human on the receiving end could not keep up. By far the most stressful job in my career.

Material Compatibility: Consider the characteristics of the materials being conveyed. Ensure that the conveyor system is designed to handle the size, weight, and composition of the materials without causing damage.

Conveyors are used when there is no alternative (weight or size), and even then, all process optimization resources must be considered prior to the installation of a conveyor. Strictly speaking, in Lean and 5s terms: a) Transport: a Form of Waste when unnecessary b) Material Accumulation: a Form of Waste if excessive WIP c) Relocate or Transfer: a Form of Waste when in excess. Sequence may be modified to bring the subsequent processes closer to each other. Conveyors should be used in limited fashion, when other alternatives are not viable.

Energy efficiency: optimise energy use through proper conveyor speed setting and energy efficiency components . Achievement the belt utilisation factor (BUF).