Going for the Long Haul

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Going for the Long Haul

November 15, 2024

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When a mine is running smoothly, it's easy to forget that heavy equipment is subject to a level of wear and tear that's rarely found in other industries. Consequently, equipment problems can escalate very quickly if not addressed within a very short time frame. In this edition of Experts Corner, Chad MacLean, Regional Operations Manager at SMS Equipment Inc., provides five tips for staying ahead of the maintenance curve.

1. Plan operations with scheduled maintenance in mind.

Proactive planning is key to keeping equipment running at peak performance. Following OEM scheduling guidelines is essential—it ensures warranty compliance and maintains equipment at optimal operation. Typically, maintenance intervals fall around 500 operating hours. In mining, where machinery often runs continuously, this interval can come up fast; at 20 to 22 hours of daily production, that means servicing roughly every three weeks.

While there's some leeway built into these schedules, extending too far beyond the recommended timing can increase the chances of wear or issues with key components. Staying as close to the recommended maintenance intervals as possible helps minimize risk and keeps the equipment running smoothly.

2. Avoid shift changes while maintenance is underway.

Ideally, keeping the same crew involved from start to finish helps ensure a smoother, more efficient service. Choosing times when the full team and managers are available, rather than during long weekends or shift changeovers, can be beneficial since it minimizes the chance of gaps in communication or oversight. When one crew can manage the service process end-to-end, it enhances continuity and helps everyone stay on the same page—what I like to call "owning it from cradle to grave."

3. Use scheduled maintenance calls to conduct planned repairs.

During scheduled maintenance, we inspect for signs of abnormal wear and often identify parts that will likely need replacement in the coming weeks or months. Scheduling those repairs during the next planned service minimizes the number of times the unit is brought into the shop and allows us to ensure that necessary parts are in stock and ready when needed. This approach also helps us forecast more accurately and strengthens our role as collaborative growth partners.

4. Communicate the impact of underservicing to all stakeholders.

Many in mining know that equipment is routinely taken out of service for maintenance but may not fully understand the consequences when maintenance is delayed. This can sometimes lead to viewing maintenance as a cost rather than an investment, creating a temptation to postpone repairs until, for instance, the next budget cycle. Often, this perspective stems from different groups within the organization having distinct priorities: reliability teams focus on long-term equipment health, operations on production targets, and maintenance on immediate functionality. When these priorities aren't fully aligned, maintenance can be seen as expendable, increasing risks.

The financial implications of delaying maintenance are significant. I've seen instances where postponing maintenance repeatedly led to catastrophic failures, resulting in a 400% increase in repair costs due to major rebuilds or, in some cases, complete equipment replacement. This doesn't even account for downtime costs and the potential need to idle other equipment while waiting for repairs.

We also stress the safety aspect. Underserviced equipment might not be safe to operate, and that is a priority that should never be compromised.

5. Maintain a long-term relationship with a trusted service provider.

At SMS Equipment, our growth has always been closely tied to the success of our customers, which is why our training and procedures are designed with their ongoing success in mind. This goes beyond technical expertise and state-of-the-art facilities—we partner with customers to help plan their maintenance strategies. For instance, if ten new trucks are put into service simultaneously, all of their suspensions will likely require service at the same time. We assist in creating a more efficient maintenance schedule that minimizes disruption to their workflow, providing tools like Gantt charts to help visualize and manage the process more easily.

We also hold reliability meetings where customers can share their goals and objectives. During these sessions, we review their long-term service needs and collaborate on ways to optimize their operations. This proactive approach helps ensure we're aligned with their goals and positioned to support their ongoing success.

The Bottom Line:

Mining equipment operates in some of the harshest conditions, and as a result, daily wear and tear can quickly lead to serious issues if not properly maintained. At SMS Equipment, we are dedicated to partnering with our customers to ensure their equipment remains in peak condition, running as efficiently as possible, and supporting long-term success.

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