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Customised Maintenance Solutions – A Comprehensive Guide

Customised Maintenance Solutions – A Comprehensive Guide

The mining industry relies heavily on its machinery and equipment. Ensuring their optimal performance through strategic maintenance is not merely a necessity but a critical investment. This guide explores the benefits of customised maintenance solutions for heavy-duty mining equipment, highlighting the importance of adapting maintenance strategies to meet specific operational needs.

Customised Maintenance in Mining Operations

maintenance working

Customised maintenance strategies play a crucial role in ensuring mining machines operate at their peak, minimising downtime and maximising productivity.

The need for tailored solutions

Mining equipment operates under some of the harshest conditions imaginable, facing extreme weather, abrasive materials, and constant mechanical stress. These factors necessitate a maintenance approach going beyond generic schedules and recommendations.

Customised maintenance considers the specific conditions under which the equipment operates, including the environment, the material being mined, and the operational intensity. By tailoring maintenance to these unique factors, owners can significantly reduce the risk of unexpected breakdowns and extend the lifespan of their machinery.

Operational efficiency and safety

There is a direct correlation between well-maintained equipment and operational efficiency. Regular, customised maintenance ensures mining equipment operates smoothly, reducing the likelihood of unplanned downtime with the potential to halt production and incur significant costs.

Plus, well-maintained machines are less likely to malfunction and pose risks to operators and other onsite personnel.

Types of Maintenance

maintenance climbing

A tailored approach to maintenance means different types of maintenance may be required. Each of these types of maintenance offers unique benefits:

Planning Ahead For Reliability

Preventive maintenance is the scheduled maintenance of equipment before a failure occurs. It’s based on time or usage criteria, such as hours of operation. The goal is to prevent equipment failure by performing maintenance tasks proactively. This approach can significantly reduce downtime and extend the life of mining equipment.

Use Of Data For Informed Decisions

Predictive maintenance goes a step further by using data and analytics to predict equipment failures before they happen. This strategy employs condition-monitoring tools and techniques, such as vibration analysis, thermal imaging, and oil analysis, to monitor the equipment’s condition and performance in real time. By analysing this data, maintenance teams can identify signs of wear or deterioration and intervene before the equipment fails.

Addressing Issues As They Arise

Corrective maintenance is performed after equipment has failed to restore it to operating condition. While this approach can sometimes lead to higher downtime, in certain contexts, it’s a necessary and cost-effective strategy. Corrective maintenance is often used in conjunction with preventive and predictive maintenance strategies to address unanticipated or unavoidable issues.

Real-Time Monitoring

Condition-based maintenance is a form of predictive maintenance involving monitoring the actual condition of equipment to decide on the necessity for maintenance. It relies on data from equipment sensors and checks by operators to monitor performance and identify potential issues.

The Future Of Maintenance Strategies

Prescriptive maintenance represents the next evolution in maintenance strategies, combining elements of predictive maintenance with advanced analytics and machine learning. This approach not only predicts when equipment will fail but also prescribes the best course of action to prevent the failure.
By analysing historical data, operational conditions, and maintenance records, prescriptive maintenance can recommend specific maintenance tasks, adjustments to operational parameters, or changes in usage practices to improve equipment performance and reliability.

Focus On Critical Components

Reliability-centred maintenance (RCM) is a strategic approach focusing on maintaining system functionality, rather than individual components. It involves identifying critical functions, understanding potential modes of failure, and implementing specific maintenance strategies to mitigate these risks.

Daily Checks: The Foundation of Equipment Health

underground maintenance

Daily checks are a critical component in a comprehensive maintenance strategy, ensuring machinery operates at peak performance and safety standards are met. This section explores the value of daily inspections, including their role in preventive maintenance and reducing downtime.

Pre-shift inspections: a must for operational safety

These evaluations are designed to identify any potential issues with the possibility of compromising the safety of the operation or the efficiency of the equipment. Key areas of focus include checking fluid levels (oil, coolant, and hydraulic fluids), examining tyres and tracks for wear or damage, and ensuring all safety devices are functional.

Routine monitoring: keeping an eye on performance indicators

This involves observing temperature gauges, pressure readings, and fuel consumption rates, among other metrics. Anomalies in these indicators can signal the onset of equipment failure, allowing for timely intervention.

Immediate reporting: the key to preventing major failures

When operators or maintenance personnel identify any signs of wear, damage, or malfunction, prompt reporting ensures these issues are addressed before they escalate into major failures. This practice supports a proactive maintenance approach, where potential problems are resolved swiftly, thereby minimising repair costs and downtime.

Benefits of Customised Maintenance Services

underground maintenance inspecting

Customised maintenance services ensure each piece of machinery receives attention tailored to its specific needs and operational demands. This personalised approach brings numerous advantages, significantly impacting the efficiency, safety, and cost-effectiveness of mining operations.

Maximising return on investment

One of the primary benefits of customised maintenance is the significant extension of equipment life. By addressing the unique wear and tear patterns and operational stresses each piece of equipment faces, maintenance plans can be designed to preemptively tackle potential issues before they escalate into major problems. This proactive approach not only preserves the machinery’s operational integrity but also maximises the return on investment by prolonging the equipment’s useful life.

Ensuring continuous operation

Customised maintenance services play a pivotal role in minimising unplanned downtimes by identifying and rectifying potential failures before they lead to operational halts. Through predictive maintenance techniques and condition monitoring, maintenance teams can schedule repairs and replacements during planned downtimes, thus ensuring continuous operation.

Lowering overall maintenance expenses

Tailored maintenance plans are designed to be as efficient as possible, focusing resources and efforts where they are most needed. This targeted approach avoids the unnecessary costs associated with a one-size-fits-all maintenance strategy, where resources may be wasted on non-critical activities.
Plus, by preventing major breakdowns and extending equipment life, the overall expenses related to maintenance, repairs, and replacements are significantly reduced, contributing to a more cost-effective operation.

Protecting workers and the environment

By ensuring all equipment operates within its optimal parameters, the risk of accidents due to equipment failure is drastically reduced. Regular and thorough inspections as part of a customised maintenance plan help identify potential safety hazards, allowing for immediate corrective actions.
As a bonus, well-maintained equipment is less likely to contribute to environmental pollution, thus supporting a mining operation’s commitment to environmental stewardship.

Continuing operational excellence with HDDSOL

At HDDSOL, our expertise and dedication to excellence guarantees your operations will gain from:

  • Expertise-driven partnership:
    Our team’s extensive knowledge and experience ensure the development and implementation of an effective and efficient maintenance strategy tailored to your specific needs.
  • Innovative technology and methodologies:
    We use the latest maintenance technologies and methodologies, including advanced predictive and prescriptive maintenance strategies, to reduce downtime and enhance productivity.
  • Customised solutions:
    Our strategies are designed to match your operational objectives, ensuring reliable and efficient equipment performance.

Our team is prepared to collaborate with you, offering the expertise, technology, and personalised solutions essential for enhancing the performance and reliability of your mining equipment.

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