Training based on a combination of industry experience and engineering expertise greatly improves design decisions.

Robert Whetstone
Vice President, Martin Engineering EMEAI (Europe, Middle East, Africa & India)

How critical is training and skilling in today’s mining equipment industry?

Training is essential to understanding how bulk materials flow through processing plants cleanly, safely and efficiently. Conveyor belts and transfer points form the critical artery through every mining operation, carrying materials between each phase of production.  Yet much of the assumed knowledge about conveyor system design and operation is inconsistent, incomplete or inaccurate, leading to all-too-common problems of spillage, buildup, dust, belt damage and in some cases total equipment failure. That can cause serious health and safety issues as well as chronic maintenance headaches and expensive unplanned shutdowns.

The source of such issues can be traced back to informal design ideas (or ‘rules of thumb’) that have emerged through historical trial-and-error and passed down through generations to become accepted as fact.  These ‘rules’ are often based on treating the symptoms of a bulk handling problem rather than addressing the root causes. Only through education and training from knowledgeable and experienced engineers can mine operators really start to understand why they are experiencing problems and take steps to resolve the issues.  Education is an investment in people and I would add that the application of any training to solve operational problems is much more cost effective than a lack of knowledge!

How has the approach towards workforce training evolved over the last few years?

Martin Engineering has led the way in terms of professional and comprehensive conveyor training, offering in-person classes, virtual training and one-on-one support.  Our Foundations™ training programme was was first introduced in 1991 as a way to package our accumulated knowledge and deliver it in an impactful, engaging and accessible way.  There are a series of Foundations™ reference books which have become an internationally recognised resource for safety, maintenance and operations training.  The 500+ page books are available in several languages and there are more than 22,000 print copies in circulation around the world.

Foundations™ marked the beginning of Martin Engineering’s commitment to enhancing conveyor system efficiency and safety through structured education and, over the decades, the program has evolved into a comprehensive, multi-level training system, encompassing several different face-to-face training courses, from beginner to advanced.

In recent years we brought our new and existing education resources together in our Foundations™ Learning Center, a comprehensive digital platform offering free, non-commercial training on conveyor operation and safety. It features a blend of articles, photos, videos, webinars, and live expert interactions, catering to various learning styles and knowledge levels. And it’s all free of charge!

The Martin Foundations™ Learning Center is structured into nine key categories, covering many aspects of bulk handling, from carryback and belt cleaning to dust management and spillage, material flow problems, preventing damage, maintenance and safety. Accessible via computer, tablet, or smartphone, it’s a valuable resource for industry professionals who want to better understand their conveyor systems. Our live webinars hosted by Martin’s top engineers are especially popular and we’re adding new sessions all the time.

Ultimately, a tailored approach is always best, and the most effective way of training workers is by examining the specific conveyor challenges at a processing plant, helping operators run safer, cleaner and more productively by learning on the job and addressing the root causes of their particular problems.

What are the key skill gaps you observe among operators, technicians, and maintenance teams handling mining equipment?

We still see gaps in knowledge and skills right across the spectrum, from the basic understanding of the characteristics of the material being processed through to belt cleaning, belt tracking and effective transfer points. There’s a lot that operators need to understand, but for most people it’s a case of they “don’t know what they don’t know” and so those accepted ‘rules of thumb’ I mentioned continue to prevail year after year.  Many commonly held views are the result of the early years of conveyor use in industrialised nations. But over the past century much has changed in the design, construction, performance and expectations of conveyors so simply doing “the same as we’ve always done” isn’t good enough for modern materials processing.

To truly understand the root causes of conveyor problems and get conveyors performing as desired requires technical knowhow and decades of lived experience – that’s what Martin engineers provide.  And there is also a need to equip the next generation of designers and engineers with the right knowledge and skills to avoid repetition of the errors associated with the handed-down design rules. Education is more important than ever with the retirement of many experienced engineers, so it’s become critical to educate younger colleagues on conveyor design and operation.  At the end of the day, training based on a combination of industry experience and engineering expertise greatly improves design decisions, resulting in higher productivity, fewer safety incidents and reduced unplanned outages.

How do you ensure that your dealers and channel partners are adequately skilled to support mining customers across India?

We work hand-in-glove with our dealers, channel partners and customers to ensure they have the right knowledge, skills and back-up support to be able to identify the root causes of a material handling issue and be able to make informed choices about the best solutions. And at Martin Engineering we’ll continue to work with all parties until issues are resolved – we’re not here to sell products, we’re here to solve problems.

For example, we pride ourselves on taking the time to travel to customer sites with our partners to conduct comprehensive audits of conveyor belt systems, known as our Walk the Belt™ programme. This ensures that the underlying issues are identified and can be solved, rather than fitting equipment that simply addresses the symptoms at one point, only to exacerbate a deeper problem elsewhere in the system.