How to Effectively Track Conveyor Performance

The last thing any company wants to commit to is purchasing an item that ultimately leads to no additional benefits. 

To make sure that any product that you buy provides measurable benefits for your business, tracking performance becomes vital. There are many ways that managers can track performance. Some of the most common ways include physical copies, digital means, and even AI. But what exactly needs to be tracked to effectively understand the benefits of a system? Is it all just statistics you can use a calculator for, or is there something beyond numbers that help realize the benefits? 

In this blog, we’ll be answering the question of how to track conveyor system efficiency. Different ways that include numbers, ease of use, and safety will be discussed. Each of the mentioned aspects plays a vital part in accumulating the final value gained from each new product. Even if you’re an expert in the industry, it’s always important to review the basics.  

As stated before, there are several different ways to measure the efficiency of your newly purchased conveyor system. One of the ways is to keep track of formulas. These formulas provide you with helpful information that will shape your perspective on how your machine is operating and how efficient it is at its job. The following are some of the most notable examples of these equations, but there are many more formulas that companies can use to measure their success. 

Conveyor Throughput 

Throughput is a major measurement of your equipment’s capabilities. It measures how much material (or product) your system can transport in a certain amount of time. The standard formula usually looks like this:

Q = p * A * V * (desired seconds/hour conversion) 

Let’s also break down the specifics of this equation. 

• Q represents your capacity (tons or kg /hr) 

• p represents material density (kg/meters cubed) 

• A represents cross-sectional area on belt (meters squared) 

• V represents belt speed (m/s) 

The ability to visualize your throughput can help tremendously in calculating your return on investment and capabilities of your conveyor.  

Belt Speed 

Belt speed is another key indicator of performance. For many different industries, the belt speed is determined by the product you’re moving, machine capabilities, and current budget. The basic formula for is:

V = π * D * N 

In this formula, the standard meaning for these symbols reference: 

• V represents belt speed (distance/min) 

• π represents the mathematical constant of Pi 

• D represents the pulley diameter 

• N represents the pulley rotational speed (RPM) 

Mean Time Between Failures 

Unlike the past two, this equation will mostly be used to track data for preventive maintenance reasons. This preventive metric shows you the average time between failures, which in turn enables you to determine the status of your system. The simple formula for mean time between failures is: 

MTBF = Total operating time/ Number of failures 

Overall Equipment Effectiveness 

This next equation has several different parts to it. It’s fairly straightforward, but always remember to measure twice and cut once. The formula (as the name suggests) produces the result of your overall equipment effectiveness. For every industry, the baseline will be different as this formula considers running time, units moved, and ideal performance rates. But in general, continually tracking this statistic will give you a good idea of your overall performance. 

OEE = Availability * Performance * Quality 

To further break this down, this is what each part represents. 

• Availability represents Run time/ Planned time 

• Performance represents Actual rate/ Ideal rate 

• Quality represents Good units/ Total units 

Conveyor Utilization 

The last equation to highlight is conveyor utilization. This formula allows you to determine whether you are overusing or underusing your current system. This, of course, is just a general representation of your conveyor’s effectiveness. Please consult any engineer or maintenance supervisor before making any changes to your current machine setup. 

Utilization (%) = Actual throughput/ Rated throughput * 100 

By tracking this, you’ll be able to see your utilization percentage over time. This percentage shows how much of the conveyor’s rated capacity is being used and whether utilization is increasing or decreasing over time. Keeping records of this statistic could guide you to saving energy, and eventually money.

Just like the formulas helped monitor the firm’s energy, safety, and financial return, digital formats can help with these issues as well.  Not only are they easy to manage, but some also come equipped with all the features that you could apply on physical records. There are several different models and products that supply excellent tracking. No specific model will be mentioned specifically, but the effects of the product will be relatively similar. 

Some of the benefits include: 

• Organized maintenance schedule 

• Central hub for records 

• Easier document access 

• Promotes recurring maintenance

The last thing that can help support increasingly busy firms is AI. Over the past few years AI has advanced in directions that were thought impossible decades ago. But now, with the ever-growing uses of AI, it has made its way into the manufacturing world. One recent development is the integration of AI with conveyor-monitoring systems. 

The recent conveyor integration with AI has allowed the equipment to keep an extra eye out for any problems or potential damages. Using both an AI model and sensors, these products can detect: 

• Belt misalignments 

• Frayed or cracked belts 

• Internal damage 

Many more benefits can arise by using AI in daily conveyor operation. These selected features demonstrate how AI may help reduce downtime, support workplace safety, and improve energy management. 

Russell Conveyor is a leading provider of conveyor systems and automation. Our team has over 20 years of experience finding solutions to our customers’ problems.  Whether you need a newly customized conveyor or need help with your preventive maintenance through our Russell+ service, we have you covered.  Don’t let today’s problems stop tomorrow’s improvement.  

Call us today at (336) 526-3014 and let’s break the boundaries of success! 

Want to learn more about AI integration, read our latest blog about the impressive technology behind this move. 

Interested in digital approaches to tracking performance, read our blog on CMMS preventive maintenance systems.