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Conveyor Audit Conducted by Our WA Support Team On-Site

Sep 24, 2024

At TSGlobal, we are committed to delivering top-tier conveyor solutions to meet the demands of industries across Australia. One of our key offerings is our thorough conveyor audit service, conducted by our expert team to ensure our clients’ systems are operating at peak efficiency. Recently, our WA (Western Australia) support team visited a client site to conduct a comprehensive on-site audit. This article provides an inside look at the process, key findings, and the value of regular conveyor audits for industrial operations.

Why Conveyor Audits Are Essential?

Conveyor systems are the backbone of many industrial operations, ensuring the smooth and continuous flow of materials in sectors like mining, manufacturing, and logistics. Over time, these systems can suffer from wear and tear, misalignment, and inefficient performance due to a range of factors. Regular conveyor audits are essential to:

  • Maximize productivity: By identifying potential inefficiencies, we help reduce downtime and ensure smooth operation.
  • Reduce costs: Spotting issues early can prevent expensive repairs or replacements.
  • Improve safety: Conveyor systems that aren’t functioning properly can pose a risk to workers, making safety a top priority in our audits.
  • Ensure compliance: Conveyor systems need to adhere to certain operational and safety standards, and audits ensure these requirements are met.

The value of a proactive approach to conveyor system maintenance cannot be understated. By regularly assessing your systems, you can avoid costly breakdowns, maintain high productivity, and extend the life of your equipment.

Preparing for the Conveyor Audit: Pre-Site Planning

Before our WA team arrived at the client’s site, extensive pre-site planning was conducted. At TSGlobal, we believe in taking a tailored approach to each audit, ensuring that our services meet the specific needs of the client’s operational setup. In this case, the client was a major player in the mining industry, with an extensive conveyor system responsible for transporting large volumes of material daily.

Our team consulted with the client’s management and maintenance staff to gain a detailed understanding of the site’s operational requirements, existing challenges, and performance expectations. Gathering this information ahead of time allows us to focus on the critical areas during the on-site audit, ensuring that we deliver the maximum value during our visit.

The On-Site Audit: Comprehensive Evaluation of Conveyor Performance

Once on-site, our WA support team carried out a thorough, step-by-step evaluation of the entire conveyor system. The audit process was designed to assess both the performance of the conveyor components and the system as a whole. Here’s a breakdown of the key steps involved in the audit:

  1. Visual Inspection: The first stage of the audit involved a detailed visual inspection of the entire conveyor structure, including the belts, pulleys, idlers, frames, and other critical components. Our team identified areas of wear and tear, material build-up, misalignment, and other signs of potential issues. By observing these elements, we could assess the overall condition of the system and begin forming a preliminary list of necessary adjustments or repairs.
  2. Component Testing and Measurement: Beyond the visual inspection, our team conducted various tests and measurements to determine the condition of individual components. For example, we measured belt tension, inspected pulley lagging, and assessed the condition of Conveyor Belt Scraper and cleaners. Component wear, if left unchecked, can lead to system inefficiencies and unplanned downtimes.
  3. Alignment Check: Conveyor misalignment can cause belt drift, excessive wear, and material spillage. Our team utilized advanced tools to check the alignment of the belt and rollers to ensure proper operation. Proper alignment not only improves the longevity of the belt but also reduces unnecessary maintenance expenses down the line.
  4. System Performance Evaluation: The next step was to evaluate the overall performance of the conveyor system. This involved assessing the speed, efficiency, and load handling of the conveyor, as well as any bottlenecks or inefficiencies in the material flow. The goal here was to identify any potential areas for optimization that could help the client improve throughput while minimizing energy consumption.
  5. Safety Assessment: Safety is a paramount concern in any industrial setting, and our audits always include a thorough evaluation of safety features and potential hazards. Our WA team checked that emergency stop systems were functioning correctly, guarding was in place where required, and safety protocols were being followed. Any potential risks were highlighted, with recommendations on how to address them effectively.

Key Findings from the Audit

After completing the on-site audit, our team compiled their findings into a comprehensive report for the client. Some of the key takeaways from this particular audit included:

  1. Wear and Tear on Conveyor Belts: The audit revealed significant wear on several sections of the conveyor belt, particularly in areas with high material load. Our team recommended immediate replacement of these sections to prevent any unexpected downtime or belt failure.
  2. Improperly Adjusted Scrapers: Our team found that some belt scrapers were not properly adjusted, leading to material build-up on the belt, which could affect belt tracking and cause carryback issues. Adjusting and calibrating these scrapers improved Conveyor Belt Cleaning efficiency and prevented material wastage.
  3. Idler and Pulley Issues: Several idlers were found to be misaligned, contributing to increased belt tension and uneven wear. Additionally, some pulleys required re-lagging to ensure smooth belt operation. These issues were addressed in our final recommendations to the client.
  4. Safety Gaps: While the client had a strong focus on safety, our audit identified a few areas where additional guarding or updated safety protocols could further reduce the risk of accidents. Our team provided suggestions for enhanced safety measures to ensure worker protection.

Delivering Value Through Customized Solutions

At TSGlobal, our conveyor audits aren’t just about finding issues; they’re about providing tailored solutions that fit the unique needs of each client. After completing the on-site audit, our WA team worked closely with the client to develop a customized action plan for addressing the identified issues.

The client was provided with a detailed report outlining the audit findings, along with prioritized recommendations for repairs, adjustments, and system improvements. In addition to immediate repairs, we also suggested a regular maintenance schedule to help the client maintain optimal conveyor performance in the long term.

The Importance of Partnering with TSGlobal

Conveyor systems are critical to the success of industrial operations, and regular audits are essential for ensuring they continue to perform at their best. With TSGlobal, you get more than just a standard audit — you get a comprehensive evaluation, personalized recommendations, and the support of a dedicated team that understands the unique challenges of your industry.

Our recent on-site audit by the WA support team is just one example of how we go the extra mile to deliver value to our clients. If you’re looking to optimize your conveyor systems, improve efficiency, and reduce downtime, our experienced team is here to help.

Conclusion

Conveyor systems are integral to industrial productivity, and their maintenance should never be overlooked. The conveyor audit conducted by our WA support team showcased the importance of regular assessments, highlighting key areas for improvement and providing actionable solutions. At TSGlobal, we pride ourselves on our commitment to helping our clients achieve their operational goals through expert audits, maintenance, and support.

Reach out to TSGlobal today to schedule your conveyor audit and take the first step toward a more efficient and reliable conveyor system.