By Sue Griffith

When operators install retrofitted conveyor solutions, they focus on the up-front price with little consideration for the cost of ongoing service, maintenance costs and supply chain. But down the road, when critical service or parts are needed, the costs related to downtime can add up quickly.

This is why having a close relationship with equipment manufacturers that offer responsive “factory direct” products and services is important to the cost of operation. The main factors to consider are service availability, technical expertise/safety and supply chain logistics.

Service technicians and certified representatives who are available during problem-free uptime are likely to be responsive during panic-inducing unscheduled downtime.

Site visits are also not arbitrary. A reputable equipment manufacturer representative will examine not just their components, but the entire conveyor system, offering preventative maintenance support. The goal is to find indicators of the causes of downtime and offer practical and timely solutions. For example, Martin’s Walk the Belt program is specifically designed for predictive maintenance. A Martin service technician or certified contractor will physically examine the entire system with an extensive checklist and then write a report, often with photos, of observations, recommendations and solutions to improve safety and efficiency.

Experts have “seen it all” until they haven’t, and that’s when their expertise is tested and safety becomes an issue. Outside service contractors may be generally familiar with systems and maintenance procedures but often face a steep learning curve when servicing new equipment designs. The top equipment manufacturers consistently iterate on previous designs, seeking to improve safety and efficiency. Factory-direct technicians and certified contractors from these reputable equipment manufacturers respond quickly to calls and arrive equipped to diagnose and solve issues, minimizing downtime.

Safety is the primary consideration for mines. If external contractors don’t operate on the same level, they risk being ejected from the site. In addition to stringent conveyor and flow equipment maintenance training, Martin techs undergo comprehensive safety training.

Often, during the installation of retrofitted equipment, some creative engineering is required to make components fit, secure and operational. Maintenance crews can’t have a replacement part for every bolt in their operation, especially if storage space is limited. This becomes acutely apparent when specialized parts are needed for repair. Equipment should have standard, easy-to-understand parts and procedures.

In addition to providing a solution, this engineering design should prioritize safe inspection and maintenance access. Whether it’s replacing wear-parts or engaging in routine service, getting the proper manufacturer parts in a timely manner is imperative.

Factory direct means that wear parts can be predictively scheduled and delivered by simply monitoring the speed at which they wear, especially for processing plants making use of remote monitoring systems. If the wear timeline is somehow shortened, this can be an indicator of upstream issues causing more wear. It can also mean that an unexpected rapid early delivery is required. Factory-direct Martin techs (and certified contractors) usually have the proper equipment in the service truck. If they don’t, depending on the remoteness of the site, they simply call, and these parts can be procured and delivered rapidly.

Walking the system and reporting observations is an important part of the process. Factory-direct expert inspection and reporting methods take a holistic view of the system. By only addressing the broken parts, upstream causes are ignored. A holistic approach recognizes and offers solutions to the causes of costly repetitive maintenance.

When operators realize the overall cost savings of the factory-direct model, then they understand how service, expertise and supply chain are intertwined to offer a full long-term solution.

Sue Griffith is a field support supervisor for Martin Engineering.