A large Corn Refiner with Automated Packaging System was installed in the early 1990s. Because of multiple acquisitions and changeover of personnel, documentation was fragmented. The system has 17 fill spouts and, 187 conveyors, five palletizers
Over four weeks, every item on every conveyor was validated, inspected, investigated and collated in individual conveyor worksheets and master bills of material. . Having belts made to length so maintenance people didn't have to search for materials, assemble the belt and then install it. Now they get the belt out of stores and replace the belt in under an hour vs. the 4-hour average. A review of findings helped customers reduce downtime by focusing on small things like establishing a lubrication schedule. Even low RPM conveyors last so much longer with lubrication, like all rotating elements. Showing the customer how lax clean up after upset conditions and the lack of job assignment meant no one doing it.
