In the mining industry and every heavily-machine-dependent industry, equipment is not just a tool, it is the backbone of every operation. From excavators to haul trucks and drills, mining equipment determines productivity. It also determines safety and profitability. Despite the critical role of equipment, many contractors make maintenance mistakes that often turn of costly for them. These mistakes reduce machine’s life-span, increase downtime and inflate operating expenses.
Any mining constructor can vouch how small oversights can snowball into massive setbacks. Here are the top 5 equipment maintenance mistakes that every contractor should avoid:
Skipping preventive maintenance: Many contractors wait until equipment breaks down before servicing it. But this reactive approach leads to higher repair costs and unplanned downtime. Preventive maintenance like regular oil changes, filter replacements and inspections, keeps machines efficient. It also helps in detecting potential issues early.
For instance if a contractor ignores his 500-hours service scheduled for his haul truck, can cause him a major setback. The delayed oil change can cause his engine to over heat, leading to a complete engine rebuild. This can cost over 20 lakhs. If preventive maintenance had been followed, the issue could have been resolved with not more than Rs. 25,000/- for oil and filter service.
Takeaway: Regular preventive maintenance like oil changes, inspections, and filter replacements save a lot of money and time in the long run.
Improper Lubrication Practices: Lubrication is the lifeline of heavy mining machinery. Using the wrong type of lubricant or over-lubricating are frequent errors that cause excessive wear and tear. It can also cause over heating and premature failure of moving parts. Contractors must always follow manufacturer guidelines. They should use high-quality lubricants and install a strict lubrication schedule.
For instance, If a contractor uses a general-purpose grease instead of high temperature grease for an excavator working in iron ore, he will suffer. Within weeks, the bucket pins and brushings will wear out. This results in a long downtime. The cost of repair will be 10x more than the price of the correct grease.
Takeaway: Follow manufacturer guidelines and maintain a strict lubrication schedule.
For instance, an operator overloads a Komatsu dump truck regularly. In a short span of time, the suspensions fail and cause a costly downtime. A simple refresher training would have prevented the misuse.
Takeaway: Trained operators increase safety, reduce breakdowns and extend machine life.
Overlooking small warning signs: Unusual vibrations, leaks, or noises often get ignore until the machine breaks down. These are often dismissed as “normal” but they can be early indicators of serious problems. Contractors, who ignore such signs, sign-up for catastrophic failures. These failures halt operations and demand expensive repairs.
For instance, a small hydraulic leak in a loader, left unchecked results in a failed pump. This shuts down the machine for a week. The repair costs Rs. 5 Lacks as compared to hose replacement of 10,000/- if addressed earlier.
Takeaway: Never ignore early symptoms. These are early warnings of bigger failures.
For instance, lack of machine maintenance means many machines missing scheduled filter change. Dust build-up leads to fuel injector damage, reducing the fleet efficiency by 15%.
Takeaway: Using a digitized maintenance tracking system would help in avoiding missed schedules and improves machine uptime.
