Abstract
Equipment is essential for the efficient execution of operations in the mining industry. The reliability and availability of the equipment is heavily influenced by efficient maintenance operations. Mining organizations face challenges such as increased operating expenses, unexpected breakdowns, and safety issues due to inadequate maintenance operations, which hinder their efforts to achieving productivity and profitability. Prioritizing effective maintenance operations allows mining organizations to optimize their operating efficiency, minimize expenses, and guarantee a safe working environment. As a result, well-maintained equipment and facilities reduce the risk of incidents and guarantee operational integrity.
The company under study has been struggling with sustaining consistent equipment availability, which has prevented it from meeting certain key performance indicators. The executive committee (EXCO) of the mine attributed this issue to the inefficient maintenance operations conducted at the mine. The objective of the study was to examine the impact of inefficient maintenance operations on organizational performance, implement corrective measures that mitigate inefficient maintenance operations, and develop a maintenance model that is appropriate for the mining company.
The study adopted a two-step exploratory sequential mixed methods approach that used a case study design to comprehensively assess the maintenance operations at the mining company. The first phase began with a qualitative phase, where site visits were conducted at the mine to gain in-depth insights into how the maintenance operations were performed at the mine. Following the qualitative exploration, the study transitioned into a quantitative phase, using historical maintenance data from the mining company. The qualitative data was used to corroborate the quantitative data and provide a comprehensive overview of the maintenance operations of the mining company. The collected data was analysed using problem solving tools and equipment reliability indicators. The problem-solving tools included Pareto Analysis, 5 Whys Analysis, and the Fishbone Diagram. For equipment reliability, the Mean Time Between Failures (MTBF) and Equipment Availability indicators were used. These tools and indicators collectively helped in diagnosing inefficiencies and assessing their impact on the mine's organizational performance. The target population for this study included the entire fleet of FEL’s (Front-end loaders) at the mine, which comprised of 12 Caterpillar loaders and 6 Komatsu loaders. The study did not use sampling methods and hence examined the entire fleet of the mine, resulting in a study population of 18 loaders.
The study conducted a comprehensive analysis that examined the impact of the identified inefficiencies on equipment performance, maintenance costs, and safety. It was discovered that these inefficiencies led to reduced equipment reliability, increased downtime, high maintenance costs, and frequent safety incidents. These factors collectively hindered the mine’s organizational performance. The findings of the study
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confirm EXCO’s claim that the lack of equipment availability was directly caused by the inefficient maintenance operations performed at the mine. By implementing the recommended maintenance model and the prescribed solutions such as investing in new equipment, enhancing training and development programs, strengthening safety and risk assessment practices, establishing performance measurement systems, and fostering continuous improvement—the mining company can significantly enhance its maintenance operations and overall performance.