MINE MAINTENANCE
Maintaining a low profile
Komatsu manufactures , sells , rebuilds , services and supports all its equipment with the aim of ensuring products comply with legislation and support low downtime and maximum productivity .
The OEM provides a number of services like training , parts support , field service , component repairs and service exchange as well as vendor-managed inventory and machine rebuilds , enabling customer support through the lifecycle of the equipment on site . Komatsu also strives to continuously improve maintenance practices , together with customers , and ensure the equipment supports this philosophy as much as possible .
Komatsu ’ s mid-size SLP loader , the SLP-6 ( WX06LP ), has recently received a facelift to optimise maintenance with the aim to improve mean time to repair and mean time before failure .
Available in both air-cooled and water-cooled versions , the SLP-6 has a bolt-off / bolt-on rear engine frame to swap between US Tier 2 or Tier 3 engine packages .
By removing the t-link and implementing the direct link design , Komatsu has seen a reduction in operating costs without compromising the tipping angle , the company says . The added benefit is a lower profile on the front side of the load frame due to lower linkage system , making it easier to navigate in a low-profile mining environment .
With a key focus on simplicity around maintainability , the LHD has been built to allow for easy access to service items . It also has centralised lubrication points to drive productivity and ease maintenance , driving improved availability .
The SLP-6 comes with a 24 V analog electric system , which , Komatsu says , is easy to maintain . It also comes with the option of having an overlayed condition monitoring system to help with performance management , maintenance and serviceability .
Other improvements like updated transmission cooling for increased cooling capacity have been implemented , while the option of bigger tyres for improved traction requirements and improved ground clearance could further aide tyre life .
All the hoses , fittings and pipes are available “ off the shelf ”, for improved maintenance planning .
levels .”
ABB ’ s level of maintenance involvement depends on the customer ’ s preferences , according to Manuell .
ABB can handle nearly all maintenance tasks if needed but also works closely with customers who prefer a more hands-on role , helping them design and implement maintenance strategies to manage significant portions of their maintenance in-house .
Assuming a low level of maturity , the first step for a customer in achieving this new standard would be to move towards scheduled maintenance activities , Manuell says , explaining that this is why the standard goes into a significant amount of detail to define optimal maintenance schedules .
“ Once this is in place , the next step is the move towards continuous monitoring of key assets ,” he added . “ ABB has developed a predictive maintenance implementation roadmap to provide structure to this process and has also released the ABB Ability™ Smart Hoisting platform which provides many of tools and functions required to move towards predictive condition-based maintenance .”
Assets with high risk of failure and high impact on safety and production should be identified as the primary candidates for predictive maintenance strategies , according to Manuell , with sensor hardware to monitor performance of these assets needing to be identified and installed . Installing sensors on high-wear parts like brakes , ropes and bearings can offer quick wins , Manuell says . These sensors can gather vibration , temperature and strain data , helping detect early signs of wear .
Alongside this , a data collection and analysis platform is needed to baseline performance , provide key performance indicators and visual representations of data that can aid in detecting deviations .
“ At an early stage of adoption , simple condition monitors should be implemented that measure aspects such as run-hours , number of operations and deviations from normal ranges , and provide alerts ,” Manuell says . “ These can be augmented by AI and machine learning once a higher level of maturity has been reached to provide more detailed assessments of asset health and the interventions required .”
Manuell says mining operations have shown great interest in the specifics behind the standards since it was launched last year .
“ We intend to review the standard periodically and track the impact on hoist availability as mining companies transition towards continuous assessment of key assets ,” he concluded .
Offsetting uncertainty with MaaS
Cummins is looking to take on the burden of engine maintenance through a customised maintenance-as-a-service ( MaaS ) model that , it
says , can offer a better way to manage workforce challenges confronting today ’ s mining operations when compared with the likes of planned equipment maintenance , maintenance and repair contract or cost per hour contracts .
In this MaaS model , some or all aspects of equipment maintenance and service work are entrusted to the OEM or a third-party specialist .
Cummins ’ MaaS through PowerCare™ Service Agreements are designed around the needs of the customer . They provide access to Cummins ’ technical support and digital monitoring solutions in a fashion tailored to a mine ’ s unique requirements .
“ Not only does this give mine operators a service that ’ s relevant , it gives them peace of mind that maintenance costs are forecasted correctly ,” Cummins says .
These contracts are easy to set up , with any local Cummins Sales and Service Center able to help design a customised plan to help maximise uptime , minimise risk and cut out unplanned costs , according to the company .
Cummins explains : “ The basic concept of MaaS is straightforward and simple : you partner with a vendor , who takes on the responsibility for specified maintenance tasks . MaaS agreements often begin with a need to fill missing skill sets . If desired , your MaaS contract can be expanded to cover all your maintenance needs through a planned transitional process .”
Overcoming headcount challenges is just one benefit of the model , yet recent innovations and a drive toward more sustainable solutions for powering equipment are strengthening the business case , according to Cummins .
“ A growing number of mining applications will soon deploy hybrid , battery , fuel cell and other alternative fuel technologies ,” the company said . “ This will have a significant impact on the training , resources and tools technicians will need to maintain them . Operators may also need to invest in skill and facility upgrades before clear winners become evident among these emerging technologies .”
This uncertainty creates risk , with every operator fearing the financial headaches – and potential ruin – of investing in a technological path which becomes obsolete too soon .
“ Under a MaaS model , much of this risk is shifted to the service provider ,” Cummins explains . “ Your vendor will be able to leverage their scale , OEM relationships and adaptability to remain capable while investing in the skills , tools and infrastructure your operation needs – regardless of the primary path for equipment design .”
Access to real-time machine data and dedicated analysis teams allows MaaS providers to monitor engine performance , detect issues before they cause costly damage and plan
28 International Mining | JANUARY 2025