OPERATIONS •
Technical expertise and safety Experts have“ seen it all” until they haven’ t, and that’ s when their expertise is tested and safety becomes an issue. Outside service contractors may be generally familiar with systems and maintenance procedures but often face a steep learning curve when servicing new equipment designs. The top equipment manufacturers consistently iterate on previous designs, seeking to improve safety and efficiency. Factory-direct technicians and certified contractors from these reputable equipment manufacturers respond quickly to calls and arrive equipped to diagnose and solve issues, minimising downtime.
Supply chain logistics Often, during the installation of retrofitted equipment, some creative engineering is required to make components fit, secure and operational. Maintenance crews can’ t have a replacement part for every bolt in their operation, especially if storage space is limited. This becomes acutely apparent when specialised parts are needed for repair. Equipment designs should have standard, easy-tounderstand parts and procedures.
In addition to providing a solution, this engineering design should prioritise safe inspection and maintenance access. Whether it’ s replacing wear-parts or engaging in routine service, getting the proper manufacturer parts in a timely manner is imperative.
Technology provides real-time status updates remotely, allowing for scheduled changes or adjustments.
Most operational site managers strive to maintain the highest workplace safety standards. If external contractors don’ t operate at the same level, they risk being ejected from the site. In addition to stringent conveyor and flow equipment maintenance training, MSTs undergo comprehensive safety training. With regular visits, factorydirect MSTs quickly learn the latest standards and procedures of each production site, staying up to date with the needs of their customers and ensuring compliance and safe working.
Research published by the Australian Coal Association indicates the cost of downtime is on the order of five times( 5x) the cost of replacing the component. When the root cause of downtime is related to the basic conveyor design, the downtime cost is approximately two times( 2x) the cost of the redesign.
Wear parts like air cannon valves can be reconstructed and sent back for less waste and better cost savings.
Factory direct means that wear parts can be predictively scheduled and delivered by simply monitoring the speed at which they wear, especially for processing plants making use of remote monitoring systems. If the wear timeline is somehow shortened, this can be an indicator of downstream issues causing more wear. It can also mean that an unexpected rapid early delivery is required. Factory-direct MSTs and certified contractors usually have the proper equipment in the service truck. If they don’ t, depending on the remoteness of the site, the MST simply calls, and these parts can be procured and delivered rapidly.
Reporting As mentioned above, after walking the system, reporting observations is an important part of the process. There is a wide difference in cost between preventative maintenance and reactive maintenance. The 2016 Maintenance Study: Seven key findings performed by Amanda Peliccione observed,“ 76 % of manufacturing
www. africanmining. co. za African Mining Publication African Mining African Mining • August 2025 • 23