Behind these delays lay several issues. Worn-out pulleys and insufficient tension were causing the belt to falter, and food residue began accumulating around the drive pulleys. Not only did this increase the risk of contamination, but it also led to operational bottlenecks. As food production halted intermittently, workers grew frustrated, and the team faced mounting pressure to meet customer demands while maintaining quality standards.
Recognising the urgency, Acoem’s team stepped in. During a thorough site visit, they used a blend of visual inspections, vibration analysis, and performance monitoring tools to understand the root causes. Here’s what they uncovered:
- Belt Slippage: The worn-out pulleys and lack of proper tension were the primary culprits, causing delays in material handling and affecting the smooth flow of production.
- Irregular Vibrations: Misaligned rollers and deteriorating bearings contributed to vibrations that threw off the system’s balance, further exacerbating the slippage issue.
- Motor Overloads: The increased mechanical resistance placed undue strain on the motor, raising the risk of failure and even longer production downtimes.
These persistent issues led to significant delays, rising maintenance costs, and unpredictable downtime, which ultimately took a toll on both production efficiency and team morale. The facility’s ability to meet customer expectations was being jeopardised, and the pressure to fix the problem was mounting.