65% Mean Brake Abuse Reduction
60% Mean Transmission Abuse Reduction
63% Mean Engine Overspeed Reduction
Machine availability is an ongoing challenge in the mining industry. Poor operator behaviors and operational practices such as abusive shifting, engine overspeed and brake abuse contribute to a loss in production while machines are down. Reactive maintenance is an inefficient way to address fleet availability and companies are more likely to suffer from heightened maintenance costs, longer periods of unplanned equipment downtime and lost mine productivity. Properly trained operators can directly reduce unscheduled maintenance costs and increase site productivity. Targeted simulation training from Immersive Technologies delivers, in the field, an average of 65% reduction in brake abuse, 61% reduction in transmission abuse and 62% reduction in engine overspeed.
Training solutions from Immersive Technologies give equipment operators the skills and understanding to operate in a productive manner while eliminating behaviors that cause machine abuse. The simulation technology includes detailed monitoring of operator behaviors which directly impact machine abuse and wear and tear including usage of brakes and gears and driving speeds. This results in an enhanced assessment tool for managers to determine which operator behaviors are most prevalent on their site and represent the greatest opportunities for cost reduction.
Let us show you how our solutions can drive results at your site.
Site identified a high number of service brake errors impacting on the safety of operators and increased wear and tear.
The project delivered an average of 40% reduction in service brake use at speed.
Iron Ore Mine, Australia
Site management identified a need to address operational performance within their Cat® 793F fleet, linked to factors impacting machine health and reliability.
Results showed a 23% reduction in total machine events per hour; and 45% spot at source time reduction.
Silver Mine, Mexico
The customer lacked a formal training process and a formal trainer on site, relying on experienced operators to train new operators using site equipment (which was not readily available).
The site's training process was completely overhauled, which demonstrated a reduction in maintenance failures of 51.6% for underground trucks and 36.7% for jumbo drills.
PT Freeport, Indonesia
FMI management wanted to improve their training programs to reduce damage, equipment downtime and accident rates during training.
After implementing a new training program, the following four months demonstrated a 35% reduction in underground loader equipment damage and 27% reduction in underground truck damage.
Westmoreland Coal Company, USA
Westmoreland needed to run an 'Run for Reliability' program that addressed abusive shifts, body-ups, overspeeds and brake temperatures.
After a five-week training program, the results showed a 61% improvement in abusive shifts, 53% improvement in body-ups, 100% improvement in overspeeds, and 75% improvement in brake temperatures.
Vostochnaya Technica, Russia
Faced with an ageing workforce in the region, Vostochnaya Technica (VT) sought to develop a new generation of equipment operators using the latest technology.
VT invested in Immersive Technologies’ simulators for operator training, resulted in a 65% of operators improved skill leading to less idle time due to unscheduled maintenance, 69% of operators improved gear selection skills and 18% of operators improved safety skills.
Liebherr T282C service brake systems were failing regularly with significant impacts on repair costs and unscheduled downtime.
After a targeted training program, number of service brake applications had reduced by 93% and maintenance spent on service brake parts reduced by $900,000 AUD.
A training needs analysis demonstrated an opportunity to improve haul truck spot times and reduce equipment damage. Though this assessment, 20% of the workforce was found to be responsible for the majority of equipment abuse and reduced productivity.
Kinross adopted a blended learning approach to up-skill operators, this process resulted in a 9 second spot time improvement ($250,000 USD cost avoidance annually), an 89% reduction in abusive shifts and 51% reduction in high brake temperatures.