ABB has completed a study to benchmark current hoisting maintenance strategies, observing that, on average, mining companies have the potential to achieve more than a month of additional production time annually by following recommended predictive maintenance strategies.

The benchmark report includes inputs from mining companies across six regions and eight different industry sectors including diamond, gold, copper and potash, to better understand the state of hoist maintenance strategies around the world. Collaborating with customers, ABB reviewed every key aspect of the hoist system. The results highlighted that mining companies using reactive maintenance could make up a gap of around 15 percent in availability compared with those already following more proactive approaches.

As ore grades in established sites become depleted while demand for resources grows, the industry is shifting to deeper mining to reach these critical resources. Mine hoists offer the most efficient way to transport heavy loads of ore from the depths, and therefore must operate at the highest possible levels of reliability and productivity. ABB identified a need for greater standardization and insight regarding optimal maintenance strategies to help its customers keep mine hoists running.

The value of predictive maintenance was reinforced through this project. Those faced with the highest levels of availability loss had, on average, dedicated less of their maintenance strategy to proactive approach versus reactive (75 percent and 25 percent retrospectively). While periodic maintenance has been implemented across hoist systems, continuous monitoring and assessment were much further behind. Of those surveyed, only 16 percent had applied continuous predictive monitoring to their mechanical systems.

Utilizing these insights, ABB devised its ‘World Class Maintenance Standard’ for hoists. While every mine hoist maintenance system should be designed for the specific requirements of individual hoists, the Standard aims to provide mining companies with a baseline for devising the optimal solution for hoist longevity. The Standard recommends that 90 percent of maintenance strategy be focused on predictive maintenance to achieve the highest availability levels.

“Hoists are one of the most expensive and vital assets within a mining operation, so keeping them running optimally is crucial for an effective mining operation,” said John Manuell, Global Service Manager for Hoisting, ABB Process Industries. “Without a thorough maintenance program, replacing these systems can be costly, risky and time-consuming. We designed the World Class Maintenance Standard to give users a benchmark to design the right program for their assets and reinforce the value, which, when fully utilized, can keep hoists running for several decades. From here, we are devising a framework to simplify maintenance services, which will be available to customers later this year.”

ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps customers in process, hybrid and maritime industries improve performance and safety of operations, enabling a more sustainable and resource-efficient future.

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