by Matthew Armstrong, MAJOR Business Development Analyst

Eager crews sometimes forget that safety and efficiency require a bit of patience. This is especially true when it comes to maintenance tasks, such as screen change-outs. To reduce impacts on productivity, crews feel the need to get repairs done quickly. However, speedy repairs, rather than getting the operation off on the right foot, often have the opposite effect. Employees in a rush take shortcuts, resulting in lower-quality repairs or worse — accidents.

Performing preventative maintenance, such as screen change-outs can help alleviate the pressure on crews by limiting repairs.

Safe media change-outs start with proper training, and before production starts is a great time to refresh training and review safety protocols. Arrange for training and other on-site technical services with reputable OEMs and dealers. This is critical for ensuring the team has the knowledge and support needed to do the job safely and efficiently when the time comes. Some manufacturers offer customized training on-demand to teach plant managers, operators and maintenance crews screen maintenance best practices.

Utilizing other services, such as vibration analysis, can also help identify maintenance issues early, allowing crews to plan ahead and limit downtime throughout the year.

Stock Up for Year-Long Productivity

Technical service visits offer a great opportunity to discuss maintenance schedules and parts needs for the year, as well. This can help producers determine exactly what parts to keep on hand, and what incentives might be available for pre-ordering critical spares, such as screen media. It’s important to thoroughly review production numbers to establish core media usage and develop a plan with a screen media manufacturer or dealer to have at least two media changeouts readily available. Some screen media manufacturers offer screen media stocking programs to ensure products are available at all times and save space onsite.

A well-curated stock of spare parts increases efficiency during spring start-up and limits downtime throughout the year — even during unplanned maintenance. This relieves pressure and allows crews to take their time for safer, more efficient change-outs.

When it’s finally time to perform maintenance, apply the same thorough planning. Create a checklist of the tools and parts necessary for the task at hand — adding a few extra bolts, washers and nuts to account for accidental droppage. A well-stocked toolbox allows for limited trips up and down the vibrating screen, reducing safety risks and fatigue for crews.

Though it should never be thought of as a replacement for PPE, some screen designs can also help reduce the risk of hand injuries. Some manufacturers include metal shrouds on all screens including woven wire screens 0.362 inches and smaller. This means no sharp edges on the wire for workers to worry about during handling and installation.

In addition to PPE, workers should never attempt to change screens alone. Working in pairs ensures available help should an individual get into a dangerous situation. Also, due to their size, most screens require two people to lift and maneuver safely. Take advantage of lifting equipment, such as zoom booms, to further reduce the risk of injury.

Workers should also be diligent about other safety measures, such as proper lock-out procedures or wearing safety harnesses if the vibrating screen is high off the ground. While these steps may seem time-consuming in the moment, they can prevent serious and even life-threatening injuries.

Safety is an Ongoing Commitment

Safety must be a top priority for crews and management. There is no way to totally relieve the pressure that comes with a delayed start due to maintenance, but operations and employees can take steps to minimize these risks. Planning ahead, working with reputable partners and practicing safety might take a little extra time, but will provide long-term benefits throughout the year.

About MAJOR

MAJOR is an innovative global manufacturer of wire screens for the aggregate, mining and recycling industries. FLEX-MAT^®, the company’s renowned line of distinctive lime-green high vibration screens made with OPTIMUMWIRE^® “The longest-lasting wire” sets the standard in lowering cost of production per ton by dramatically increasing throughput and wear life while eliminating blinding and pegging. MAJOR masters wire quality, screen manufacturing and the screening process, and provides on-site screening performance assessment and training seminars on screen maintenance and screening efficiency to help producers increase their screening performance and profitability. MAJOR is a Haver & Boecker company. MAJOR, 225 North Montcalm Blvd., Candiac, Québec, Canada J5R 3L6; Phone 450 659-7681, Fax 450 659-5570; info@majorflexmat.com; Twitter; Vimeo; LinkedIn; Facebook; or www.majorflexmat.com.