How to Calculate Production if My Crusher Runs Intermittently?

Calculating production for a crusher that operates intermittently requires a systematic approach to account for the periods of operation and downtime. Here's a general guide on how to do this:

1. Determine Operating Time:

   • Record the actual time the crusher is in operation during a given period (e.g., daily, weekly). This excludes downtime for maintenance, repairs, or other interruptions.
   • If possible, automate data collection through sensors and monitoring systems to ensure accurate logging of operation times.

2. Capacity Assessment:

   • Know the crusher's design capacity, which is typically measured in tons per hour (TPH).
   • Take note of any factors that might affect this capacity, such as the hardness of the material being processed or whether the material is wet or dry.

3. Production Rate Calculation:

   • Use the formula: $$\text{Production (tons)}=\text{Operating Hours}\times \text{Capacity (TPH)}$$
   • Sum up the production over the different operating intervals to get the total production for the desired period.

4. Adjust for Efficiency:

   • Account for the operating efficiency; no crusher operates at 100% efficiency due to factors like setup time, efficiency loss over time, or suboptimal operating conditions. This efficiency can be estimated based on historical data or industry standards.
   • Adjust production using the formula: $$\text{Adjusted Production (tons)}=\text{Production (tons)}\times \text{Efficiency (\%)}$$

5. Document Downtime Reasons:

   • Keep records of reasons for downtime to identify recurring issues or areas for improvement. This could include maintenance, power outages, or material handling issues.

6. Regular Review and Optimization:

   • Regularly review production rates and downtime logs to identify trends or possible improvements. This could involve equipment upgrades, better maintenance schedules, or process optimizations to reduce downtime.

7. Use Software Tools:

   • Consider using manufacturing execution systems (MES) or other industrial software that can automate data collection and analysis, providing real-time insights into production and efficiency.

Applying these steps consistently will help you accurately calculate production and make informed operational decisions even when your crusher runs intermittently.