Canada’s mining industry is the backbone of many provincial economies, but operations for the entire industry rely on just a handful of large, heavy-duty components. These critical parts directly impact production, profitability, and the long-term viability of mining operations. However, the growing challenges of global supply chain disruptions, characterized by unprecedented lead times for essential equipment, are forcing a fundamental shift in how Canadian mines approach machinery maintenance. Routine and proactive maintenance is no longer just a best practice – it’s a critical survival strategy.
The reality of supply chain vulnerabilities
The global supply chain crisis has exposed significant vulnerabilities in the mining sector. Consider the lead times for key components: large power transformers, vital for powering entire mine sites, now require three to five years for delivery. Girth gears, essential for grinding mills, face lead times of six to twelve months. These delays can cripple operations.
Many Canadian mines face additional challenges. Remote locations, harsh weather conditions, and reliance on specific transportation infrastructure add layers of complexity. A broken-down transformer in a mine accessible only by road can mean weeks, if not months, of lost production.
The consequences of equipment failure can be financially devastating. A single transformer failure can halt production, resulting in millions of dollars in lost revenue and potential reputational damage.
A site’s infrastructure is also deeply interconnected. Drills, crushers, conveyors, and electrical grids all rely on each other. A failure in one area can trigger a cascading effect, bringing the entire operation to a standstill.
Proactive approach: A seven-factor framework
The key to mitigating these risks lies in adopting a structured, proactive approach. FM’s best-practice model is a seven-factor risk assessment framework that helps operators identify critical exposures early, prioritize action, and fund mitigation strategies. This model focuses on both the “frequency drivers” and “severity drivers” of equipment failure.
Frequency drivers include:
- Operating conditions: High stress and harsh environments accelerate wear and tear.
- Physical environment: Climate considerations, such as extreme temperatures and seasonal changes, demand specialized maintenance protocols.
- Operator training: A skilled workforce is crucial for proper equipment handling and early detection of potential problems.
- Maintenance practices: Preventative maintenance schedules, including regular inspections and lubrication, are essential.
- Operating history: Learning from past incidents and identifying recurring issues is vital for continuous improvement.
Severity drivers include:
- Safety devices: Testing of instrumentation to prevent excessive damage to equipment in the event of a problem.
- Contingency planning exposures: Having well-defined plans in place for various failure scenarios is key.
Proactive approach
Taking a proactive approach with preventative measures is a cost-effective investment compared to the potential costs of downtime. Routine condition monitoring, such as vibration analysis and thermal imaging, can detect potential problems early, allowing for timely repairs and preventing catastrophic failures. Additional measures can include non-destructive testing of critical gears, and inspection of highly stressed components and hoists. Operator training refreshers ensure proper equipment handling, minimizing the risk of human error. Contingency plans provide a roadmap for responding to emergencies, minimizing downtime and mitigating potential damage.
While stockpiling spare parts may not always be feasible due to cost and storage limitations, a well-documented contingency plan is essential. This includes:
- Pre-negotiated access to mobile substations (or other critical equipment).
- Detailed engineering drawings for rapid repairs.
- Clarity on fabrication timeframes for replacement parts.
Looking ahead
Taking a proactive approach with preventative measures and robust contingency planning is becoming increasingly important for mining operations in Canada and around the world in the face of ongoing supply chain challenges.
By embracing a proactive approach, focusing on risk assessment, and investing in preventative measures, mining companies can mitigate the impact of supply chain disruptions and ensure the long-term viability of their operations.
Learn more about FM’s proactive maintenance solutions for the mining industry here.
