What was the site experiencing?

Machine performance and frequent breakdowns that were due to a combination of incorrect parts and incorrect procedures. The setup of the machine was not done to correct geometry, which is critical for the machine to run as per design. The parts problem was partly due to the machine’s age, and that information was hard to source. The procurement of incorrect parts and combinations of parts supplied by various suppliers were unsuitable for the machine.

Main problems identified.

The key factors that were involved were that the site was using a contractor hire company to do the major rebuilding of these machines. The contractor hire team had limited knowledge of this equipment and was supported by a site maintenance team that had rebuilt these machines several times. Over the years, they have lost some experience, confidence, and technical knowledge. The main problem addressed was the incorrect procedures and unsupported information, along with personnel not having the knowledge and training to identify and rectify the problems. This unfortunately led to an incorrect setting up of the machine geometry, and the machine ran out of specification.

Solutions and recommendations.

Crushology’s strategy was to first do a parts audit and machine audit to identify the incorrect parts. An engineering company was instructed to manufacture and procure the correct parts. The other recommendation was for a Crushology technical representative to be onsite to assist with the installation of new parts, followed by the correct setup of the machine geometry. Crushology’s key recommendation was to conduct classroom and on- the- job training on the technical aspects of the machine and to understand the key importance and the setup of machine geometry. The site maintenance superintendent agreed that this was a positive way forward to invest and share the knowledge within the maintenance team and to instil confidence in the work force. Crushology recommended to follow up with ongoing training.

Testimony from site representative

Crushology has delivered the required in-depth knowledge and technical ability to restore the reliability of our critical machines. Crushology has provided excellent training for my team and has provided them with the knowledge and confidence to execute the correct procedures to setup the clearances and geometries of these machines and know the small but important details to look out for.

Their assistance has been invaluable and allowed us to be self sufficient and not be reliant on contractor availability in a major breakdown situation.

Elton Smith
Maintenance Superintendent