RAM (Reliability, Availability, Maintainability) Study to Optimise Operational Efficiency in the Mining Industry
PROJECT
CONSULTANTS
RELIABLITY
ENGINEERS
YEARS OF
PARTNERSHIP
CHALLENGES
Due to the harsh operational environment, equipment failures were frequent and led to unplanned downtime, reduced production, and increased maintenance costs.
THE OBJECTIVES
The key objectives of the RAM study were:
• To improve the reliability of critical mining equipment and reduce unplanned failures.
• To increase equipment availability to maximize production output.
• To optimize maintenance practices, ensuring the right balance between preventive and corrective maintenance.
• To provide a framework for ongoing monitoring and continuous improvement of equipment performance.
OUR APPROACH
1. Data Collection and Equipment Assessment
The first phase involved an extensive data collection process to assess the current state of equipment performance and reliability.
• Historical failure records: Equipment failure logs, repair history, and downtime data for haul trucks, excavators, crushers, and conveyor systems.
• Maintenance schedules and records: Documentation of preventive maintenance activities, corrective repairs, and the frequency of unplanned maintenance events.
• Operational conditions: Environmental factors (dust, temperature, humidity) and their impact on equipment wear and tear.
• Operational efficiency: Production delays, throughput rates, and overall equipment efficiency (OEE) metrics.
2. Reliability Analysis
Assetonix performed a detailed reliability analysis to understand the failure patterns and identify high-risk components. The reliability analysis included:
• Failure Mode Effects and Criticality Analysis (FMECA) crusher bearings.
• Statistical Reliability Analysis
• Mean Time Between Failures (MTBF)
3. Availability Analysis
The availability analysis focused on determining the overall equipment availability (OEA)
• Operational Availability (Ao)
• Downtime Analysis
• Production Impact Assessment
4. Maintainability Analysis
To optimize maintenance practices and ensure minimal equipment downtime, this includes:
• Mean Time to Repair (MTTR)
• Maintenance Strategy Review
• Maintenance Resource Optimization
5. Development of a Comprehensive RAM Strategy
Key elements of the strategy included:
• Predictive Maintenance (PdM) Implementation
• Preventive Maintenance Optimization
• Spare Parts Management
• Maintenance Team Training
THE RESULTS
The RAM study delivered significant improvements in equipment reliability, availability, and maintainability, leading to measurable operational and financial benefits for the company:
• Increased Equipment Availability
• Reduced Downtime
• Improved Reliability
• Lower Maintenance Costs
RAM (Reliability, Availability, Maintainability) Study to Optimise Operational Efficiency in the Mining Industry
PROJECT
CONSULTANTS
RELIABLITY
ENGINEERS
YEARS OF
PARTNERSHIP
CHALLENGES
Due to the harsh operational environment, equipment failures were frequent and led to unplanned downtime, reduced production, and increased maintenance costs.
THE OBJECTIVES
The key objectives of the RAM study were:
• To improve the reliability of critical mining equipment and reduce unplanned failures.
• To increase equipment availability to maximize production output.
• To optimize maintenance practices, ensuring the right balance between preventive and corrective maintenance.
• To provide a framework for ongoing monitoring and continuous improvement of equipment performance.
OUR APPROACH
1. Data Collection and Equipment Assessment
The first phase involved an extensive data collection process to assess the current state of equipment performance and reliability.
• Historical failure records: Equipment failure logs, repair history, and downtime data for haul trucks, excavators, crushers, and conveyor systems.
• Maintenance schedules and records: Documentation of preventive maintenance activities, corrective repairs, and the frequency of unplanned maintenance events.
• Operational conditions: Environmental factors (dust, temperature, humidity) and their impact on equipment wear and tear.
• Operational efficiency: Production delays, throughput rates, and overall equipment efficiency (OEE) metrics.
2. Reliability Analysis
Assetonix performed a detailed reliability analysis to understand the failure patterns and identify high-risk components. The reliability analysis included:
• Failure Mode Effects and Criticality Analysis (FMECA) crusher bearings.
• Statistical Reliability Analysis
• Mean Time Between Failures (MTBF)
3. Availability Analysis
The availability analysis focused on determining the overall equipment availability (OEA)
• Operational Availability (Ao)
• Downtime Analysis
• Production Impact Assessment
4. Maintainability Analysis
To optimize maintenance practices and ensure minimal equipment downtime, this includes:
• Mean Time to Repair (MTTR)
• Maintenance Strategy Review
• Maintenance Resource Optimization
5. Development of a Comprehensive RAM Strategy
Key elements of the strategy included:
• Predictive Maintenance (PdM) Implementation
• Preventive Maintenance Optimization
• Spare Parts Management
• Maintenance Team Training
THE RESULTS
The RAM study delivered significant improvements in equipment reliability, availability, and maintainability, leading to measurable operational and financial benefits for the company:
• Increased Equipment Availability
• Reduced Downtime
• Improved Reliability
• Lower Maintenance Costs
