Unplanned haul-truck engine downtime cut 15% for an alumina miner

Alarm, work-order and telemetry history turned into early warning of the engine and overhaul failures that drive a mining fleet's unplanned downtime.

Challenge

The miner was expanding production across two mine sites, and its mobile fleet set the pace. Unplanned maintenance on the haul trucks cost throughput, and fixed service intervals set the workshop's calendar, whatever condition each truck was in. The fleet's vehicle health system raised more than a hundred types of alarm, and the most frequent ones said little about a truck's real condition.

Solution

With an engineering partner, Arundo ranked the fleet's unplanned work orders by cost and downtime, and picked out the failure modes that mattered most: engine work and major overhauls. Correlating six years of work orders with the alarm history showed that distinct alarm patterns appear in the month before those failures. Oil-sample data and critical trends were matched to each truck, and models built on them warn the maintenance team which truck to bring in, and why.

Impact

15% reduction in unplanned engine-related downtime, in a pilot on the haul-truck fleet.

MORE IN METALS & MINING

All stories
  1. METALS & MINING Engine Monitoring for Heavy Equipment DealershipData-driven insights to improve heavy equipment maintenance and reduce downtime. LEVEL 1
  2. METALS & MINING Raw-mill liner wear forecasting and gearbox failure monitoringA forecast of the day the mill's roller liners reach their wear limit, and a continuous gearbox health metric trained on the failure the plant had already lived through. LEVEL 1
  3. OIL & GAS 1000x speed increase in fatigue monitoring of flexible risers1000x faster fatigue insights than traditional FEA models, at over 98% accuracy. LEVEL 1

Where is your plant on the scale?

Thirty minutes with our team, and you'll know your plant's level, the constraint holding it there, and what Level +1 is worth to you.

Find your plant's level Book a level assessment