How Poor Conveyor Design Leads to Project Delays and Cost Overruns

Sep 28, 2023 | Conveyor Design | 0 comments

For the world of systems integration, a well-executed conveyor design is significantly important for the timely and efficient production and movement of goods. In particular, conveyors serve as the central nervous system of the material handling  process, silently and diligently transporting materials from one production area to another and thus ensuring a seamless operation of your entire industry. These dependable workhorses serve a diverse set of manufacturing and distribution processes, offering a streamlined method for material handling and operational efficiency.

At the same time, while such conveyor systems are crucial to the industry, they also represent a potential point of failure. If not given due attention, even the smallest flaw in their design can cause a chain reaction of negative events, leading to a breakdown within the entire industry.

In this article, we will delve into how poor conveyor design causes unexpected project delays and substantial cost overruns, shedding additional light on how conveyor systems impact projects, what design flaws often look like, and how to avoid such issues. These strategies will equip you with the knowledge to steer clear of potential problems, guaranteeing the smooth and efficient execution of your future projects.

The Critical Element of Conveyor Design in Combatting Project Delays

Conveyors are the literal movers of industry, playing an indispensable role in transporting raw materials, components, and finished products across different stages of the production process in a timely manner. An optimally-designed conveyor system guarantees that your operations are streamlined, the product requires minimal manual handling, and the risk of bottlenecks is effectively reduced. Each of these factors directly influences the overall project’s efficiency and productivity.

On the other hand, a conveyor system that hasn’t been properly integrated into the overall workflow can result in delays and a failure to manage the intended load efficiently. Such a poorly designed conveyor often results in operational inefficiencies and can pose safety hazards. Even worse, this faulty system may further lead to a complete breakdown and a full production line down. This is not merely a hypothetical situation for illustrative purposes but a real-life challenge that can disrupt the smooth operation of your project.

 The Impact of Poor Conveyor Design on Cost Overruns

A secondary issue that arises when a conveyor system is poorly designed is the need to continually address problems with costly repairs. Typical errors include an inappropriate selection of the conveyor type, the use of low-quality components, poor layout, and incorrect sizing. No matter what the root of the poor conveyor design returns to, such issues will significantly impair the entire system’s functionality and result in even costlier outcomes. Such outcomes include frequent breakdowns, increased maintenance needs, and reduced operational efficiency.

The economic issues that stem from poor conveyor design are real problems that industries often grapple with. For example, consider a manufacturing plant with an unsuitably-sized conveyor repeatedly overloaded with products. In such a case, the commercial setting is faced with costly overruns due to the conveyor system’s operational bottlenecks and frequent breakdowns. In a world where time is money, a manufacturing or distribution center will continue to struggle with a system that does not match its operation’s natural flow, hindering its overall productivity and severely threatening the entire business.

 Actionable Tips for Systems Integrators

As a systems integrator, you must acknowledge that even minor malfunctions within a system can stall an entire production line, resulting in idle labor and equipment, and that greater breakdowns require significant resources for repairs and recovery. It is your responsibility to ensure that every cog in the machine, and especially with the conveyor system, is operating at its optimal level. From the initial stages of design to its final implementation, you are required to guarantee that the conveyor system aligns perfectly with the needs of the project. It is certainly a challenging task, but this is what makes your role so vital to the overall success of the industry.

To effectively avoid the pitfalls of poor conveyor design, consider the following strategies for future success:

Strategy 1: Verify Product Information: Always confirm and crosscheck information about the products that a conveyor system will handle. This includes details about the weight, size, and overall dimensions of products and how the goods will interact with the conveyor’s overall environment.

Strategy 2: Conduct Rigorous Testing: Take the time to invest in conducting thorough, real-world condition simulations to identify potential malfunctions. This step is integral to building a reliable and long-lasting conveyor system.

Strategy 3: Use Design Tools to Mitigate Risk: Advanced design tools can be your strongest ally in mitigating risks associated with conveyor design and will help you significantly reduce the risk of project delays and cost overruns. Specific tools like throughput calculations and 3D visualizations simulate conveyor operations, further enabling you to identify and correct design flaws before implementation.

Strategy 4: Choose a Quality Partner: The right conveyor system design partner who brings deep expertise to your project can make a world of difference to your entire industry. Ensure that you will be working with a provider who offers expert advice, quality craftsmanship, and effective design tools.

  How Power Pack Supports Systems Integrators

 When it comes to conveyor systems, high maintenance often goes hand-in-hand with excellent performance. The more complex a system, the more it can accomplish, but the more expertise it requires to design, implement, and effectively maintain. It is in this arena that a provider with deep experience becomes invaluable. Having already been through the trenches numerous times, they have solved a multitude of problems, successfully navigated projects like yours in the past, and now bring a vast knowledge of the best practices to implement. Best of all, such a provider can guide you around common pitfalls and thereby significantly decrease the risk of project delays and cost overruns, ultimately contributing to a smoother implementation process and a more efficient operation.

In seeking to prioritize experience, this is precisely where we at Power Pack Conveyor Company come in. With nearly 100 years of deep expertise in conveyor design and manufacturing, , we are committed to helping you navigate your project’s complexities and ensuring a successful outcome for each one of your industry goals. Furthermore, we provide robust support by offering high-quality conveyor craftsmanship,  advanced design tools, and seasoned engineering experience. Our professional designers and rigorous testing protocols help mitigate any risks associated with poor conveyor design and guarantee a successful outcome for your entire project.

 Join Power Pack to Drive Project Success

Do not let poor conveyor design derail your project. Reach out to us at Power Pack Conveyor Company today and explore how we can assist you in designing and implementing efficient and reliable conveyor systems. Remember that investing in the right design right now will save you from possible delays, cost overruns, and headaches down the line. Partner with us for smoother project implementation and improved operational efficiency.

About the Author

Dan Farrar is the CEO of Power Pack Conveyor Company, a pioneering industrial conveyor manufacturer since 1929. Power Pack Conveyor Company specializes in designing, engineering, and manufacturing conveyors, conveyor components, and turn-key systems for OEMs, System Integrators, and Distributors.

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