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Start of Shift (Pre-Plan) Activities Check in (Time Clock) Put on work clothes Steel tip shoes Must be minimum 6" boot Report to lunch room Receive job assignment from supervisor Obtain work order Work order number for time card and for charge card Equipment number Work order description Who originated the work order Discuss special instructions as needed Discuss safety issues of job Inquire if job area has been cleaned Walk to shop Watch for traffic Watch for wet/icy surfaces Obtain PPE located in shop Get hard hat Get hearing protection Ear plugs Muffs Get gloves Get respiratory protection Get safety glasses Get safety locks Receive further job instructions from lead person (Clip process/Vulcanizing process) Assign mobile equipment Pre-shift inspection Show Pre-Operational power  point presentations Forklift/gradall Repair truck Obtain materials and parts Complete charge out slips Turn charge slips into store house Use forklift to remove conveyor belt (24") from storage area Prefer using forklift Get belt clips (190 type clips) Explain why this size/type of clip is used  Get belt tape Obtain tools Radios Minimum of 3 plant radios required Two belt clamps/blocks 24 inch, 190 template Framing square Four come-a-longs One chain wrench (3 ton) Two 5/8-inch x 4 ft. slings Two chains (3/4 inch) Two 1/2-inch drive electric impact wrenches #1 belt punch #1 nut driver Two stud breaker bars One 4 1/2-inch electric grinder   Face shield One claw hammer Two utility knives with spare blade Combination wrench set Socket Set (1/2-inch drive) Light cord with gfci Shaft and bearing assembly Two clevises Two 5/16 chains 1/2-inch cable (min. 25 ft.) Six 1/2-inch cable clamps Danger tape Torch and burning goggles Belt clevises Two 2" x 12" x 36" boards/planks One spool 3/4" hemp rope Punch quick connect for impact wrench Tool bag Each person is responsible for their own tool bag Call Central Control Review company policy Report names Report clock numbers Report equipment I.D. being worked on Report what job description Have control room place crt. #1, belt #1 and #2  in the "jog" mode Perform mobile equipment pre-shift inspection Fill out pre-shift inspection check list Report or correct any problems Refuel equipment as needed Discuss HazCom regulations Load materials and tools onto truck Load belt onto forklift or gradall Discuss qualifications to operate equipment Proceed to job site Observe speed limit Watch for foot traffic Watch for equipment right-of-way Stay 40 feet from mobile equipment while walking Beware of restricted areas Perform the Job Arrive at job site Observe work area upon approach Park truck in safe area Chock wheels Perform work place examination Correct or report safety defects Verify that crew is at correct belt by visual observation Lock equipment out Each individual applies his/her own locks Review company lock out policy Apply locks on crt. #1 belt #1 Try to jog belt #1  to make sure belt will not start Apply locks on crt. #1 belt #2 Try to jog belt #2 to make sure belt will not start Unload tools at tail pulley at belt #2 All tools except 3-ton chain wrench and 3/4" chain Bring adjustable wrenches Remove wheel chocks and drive to head pulley area Park truck and chock wheels Unload tools at gravity take-up Remove the gravity take-up guards Install the chain on beam above the center line of the gravity take-up weight Connect 3-ton chain wrench to the chain Verify safety latches on hooks Weight limitations in effect Connect the chain wrench lifting hook into the gravity weight take-up lug Verify safety latches on hooks Lift the gravity take-up into the halfway position using the 3-ton chain wrench Explain this procedure Close the gravity take-up guards Back off tension on belt scrapers Remove chocks and drive back to tail pulley Park truck and chock wheels Use forklift/gradall to put belt into position at tail pulley area for installation Install shaft/bearing assembly into the core of the new belt Verify belt is not hung backward Install the two 5/16" chains to the overhead beams Minimum 5/16" Watch your loading capacity Hook one come-a-long to each chain Close safety latches on hooks Install one clevis to each bearing Connect each come-a-long lifting hook to each clevises Close safety latches on hooks Use come-a-long to lift new belt about 6 inches off floor Remove guards from tail pulley area Remove skirting from tail chute Install belt clamp at Grimmies bridge Explain that hemp rope can be used here.  Do not use rope on incline belt Remove belt covers, if necessary Connect two come-a-longs to the belt clamp Close safety latches on hooks Install two cables around the next set of idlers Connect come-a-longs into the two cables Close safety latches on hooks Explain when necessary why chains are used instead of cables Tension the come-a-longs Install the plank underneath the bottom of the top belt Set the framing square on the belt top cover and square it with the belt above the plank Use the utility knife to cut the belt using the framing square as your guide cutting away from your body Pull the non-clamp belt end through the tail pulley Cut bands on new belt Stay clear - explain danger of release energy Pull and feed the new belt end over the tail pulley and through the wall to the old belt end Square the new belt end up to the old belt end Install planks under both belt ends Using the top part of belt clip, mark six sets of holes evenly spaced across belt ends Use the electric impact wrench with a #1 punch and quick connector to punch holes into the belt ends Install clips through bottom side of belt ends through the punch holes Install top of belt clips and nuts Tighten each nut using the impact wrench and nut driver Make sure clip ends are countersunk in top cover of belt ends Use breaker bars to break stud from all six clips Remove come-a-longs, belt clamp, planks, and both cables Install belt clevis on old return end of belt using 1/2" bolts Holes must be punched prior to attaching the clevis Tighten the bolts on belt clevis Install one end of the 25' cable through the belt clevis cable Use three 1/2" cable clamps to fasten a loop around the belt clevis cable Explain properly installed clamps Danger tape all affected areas Contact pay loader operator using plant radio  Make a loop in the cable fastening with three 1/2" cable clamps Reinforce cable clamps proper installation/configuration Connect the loop of the cable to pay loader's hitch pin All personnel must remove locks from belt #2 Verify that radios are working properly Spot personnel to the proper location all with radio using Channel 3 Still need to have people (possibly more people) to communicate without radios Assign one to tail pulley Assign one head pulley Assign one with splice Assign one outside with pay loader Verify communication with each person Put the disconnect switch into "On" position Stand to the side of the disconnect switch throwing switch while facing away from it Verify that safety lanyard is operating by using "jog" Explain safety switch procedure Reset safety lanyard Call to make sure that all personnel are clear and ready to pull belt Explain procedure of removing old belt Begin "pulling" belt using radio communication between "jogging" and "pulling" with pay loader  Continue the "pulling" process until the new belt is all the way around Lock #2 belt out All personnel install their locks Disconnect the cable from the pay loader's hitch pin Release pay loader operator Disconnect cable and belt clevis from belt Place cable and belt clevis on truck Cut the old belt from the new belt Feed new belt through tail pulley to other end of new belt Install one belt clamp on each end of belt Explain this process on distances between belt clamps Install come-a-longs to belt clamps Close safety latches on hooks Use come-a-longs to remove belt slack Place plank under the top belt Square belt ends Explain this procedure Nail one end of belt to the plank Install splicing template Explain this procedure Install holes in belt through template Explain this procedure Remove template from belt Put clips into one end of belt Follow manufacturer's procedures Turn template upside down and slide onto bolt of clips to line up with holes Take other end of belt and install clips into holes Install top half of clips with nuts (hand tight) Install belt tape to seal the joint Ensure splice is square Tighten all nuts on clips with impact wrench Explain the procedure Use breaker bars to break off all clip bolts Grind the clips with a 4 1/2" disc grinder Must wear full face shield Grind bolts flush with nuts Remove nail from belt Remove planks from belt Remove the belt blocks and come-a-longs Install skirting and guards on tail pulley Reinstall all belt covers Go to the drive end of belt and lower gravity take-up Remove chains and chain wrench Install guards at gravity take-up Re-tension belt scrapers Explain this procedure Remove all locks Belt #1 Belt #2 Put disconnect switch to the "On" position Stand to the side of the disconnect switch throwing switch while facing away from it "Jog" and "train" belt Check and replace all bad idlers, as needed Lock belt out before any idler replacement is started Release system to Central Control Clean-up Gather all tools up and load them on the truck If torches were used, gases must be bled Show video Before moving truck, ensure chocks are removed Pick up all debris Clean up old belt Roll up and move with gradall/forklift Clean up, remove new belt on roll, and return to belt storage location Remove danger tape Perform workplace inspection Correct any deficiencies Ensure all locks are off Ensure all disconnects/lanyards have been place in the "on" position Call Central Control Report names Report numbers Report equipment I.D. Verify "ready" light Return to shop Park truck in front of shop Chock truck wheels Remove debris from truck and place into proper containers Unload tools/equipment from truck Visual inspection of your tools Replace/repair damaged tools Store tools in proper location Remove chocks from wheels Drive truck to wash rack Clean truck Blow off/high pressure wash Drive truck back to shop Chock wheels Ensure personal and company tool boxes are locked End of Shift Ensure that all parts have been charged out and slips turned in Fill out work order and explain the work performed Fill out time card Place all paperwork into box in front of shop Notify supervisor of job completion Root cause analysis meeting Hold job critique meeting Improve job efficiency  Improve job safety Abnormal conditions  dictate discussions Shower up Check out