Optimising results and ROI from conveyor safety training

The hours spent training production and maintenance teams can lead to variable results. Staff might simply tick the boxes without delivering a return on investment, or the training can enhance safety, foster team building, and develop a deeper understanding of the equipment that boosts efficiency and uptime.

Training should be robust and encourage problem-solving using modern methods and standards. Companies that prioritise safety experience fewer incidents, reduced regulatory oversight, and higher productivity and profits.

When it comes to conveyor belts, a one-day training session can serve as a refresher, but it is recommended that staff complete a comprehensive course lasting at least two days. Conveyors are as complex as they are crucial to operations, and training should include a mix of classroom and hands-on learning, followed by a pilot programme to encourage team building and gauge results.

The problem

A commitment to safety starts at the top with corporate culture. A “production-at-all-costs” approach means safety concerns are always present. Bad habits and injuries often stem from three things:

• lack of funding
• an understaffed maintenance department
• a 'run-till-broke' mentality

Good safety habits require training and the patience to follow extra steps. Cutting corners and labelling it “efficiency” can lead to serious injuries, low morale, downtime, and lost production.

Basic training

Everyone who operates, cleans, or maintains conveyors should be trained on the hazards of bulk material handling. Basic training helps staff identify problems and resolve them safely. Appropriate safety training emphasises a fundamental understanding of conveyor design and operation, as well as the Lock-Out Tag-Out (LOTO) procedures required for working on and around the system.

Advanced training

Over time, production demands can cause the conveyor belt speed and capacity to exceed the original design specifications. Systems are incrementally modified to minimise problems associated with these demands. Advanced conveyor design training for engineers and mechanics is critical for diagnosis and the development of updated solutions. No two conveyors are identical, so adhering to standard design methods allows a technician to make adjustments that another can recognise and understand.

Day one

A walk-down of “problem belts” before the training helps the instructor focus on site-specific issues and management’s expectations. The first day begins in the classroom, with the group reviewing typical problems, discussing challenges, and learning best practices for addressing them safely. The class identifies a couple of problematic conveyors and splits into small teams. Each team examines the same issue and brainstorms solutions.

Day two

The class reviews and discusses root causes, solutions, and procedures. Once the teams reach an agreement, they prepare a short presentation using the knowledge they have gained. These presentations may also include an estimate of the cost of the proposed solutions.

Management is then invited to listen to the presentations, ask questions, and demonstrate a commitment to safety and communication. By presenting, trainees show their understanding of and support for the solutions. It is critical that the attending manager(s) have the authority to act on the proposals and are willing to commit to a pilot programme to demonstrate that theoretical results can be translated into practice.

Pilot programme

One or more conveyors from the presentations are selected for a pilot programme. Usually, the results of the pilot programme are immediately noticeable. A lapse in maintenance can affect the results, so the test period should be extended to the next scheduled shutdown, with periodic inspections and adjustments carried out by the equipment manufacturer.

Conclusion

It is incumbent upon management to take safety and maintenance training as seriously as the staff, listen to employees’ concerns, and fix issues correctly the first time. As research has shown, companies that prioritise safety, training, and equipment upgrades experience fewer incidents, less regulatory oversight, higher productivity, and greater long-term profits.

The online Martin® Foundations™ Learning Center draws on the collective knowledge and expertise gathered over more than 80 years of solving bulk-handling challenges. Aimed at apprentice technicians and experienced engineers alike, the non-commercial information is offered at no charge and is accessible via computer, tablet, or smartphone. An extension of the Foundations training curriculum, the Learning Center uses a mix of text, photos, videos, webinars, online events, and live experts available to answer questions.

Read the article online at: https://www.worldcement.com/product-news/26112025/optimising-results-and-roi-from-conveyor-safety-training/