A Sany 47m concrete pump truck is operating at the construction site, and workers are cleaning the pump truck after pouring.

A Sany 47m concrete pump truck is operating at the construction site, and workers are cleaning the pump truck after pouring.

Full Fleet Maintenance & Overhaul for a Mining Operation

Client Background

A large open-pit mining operation in Africa was facing 20%+ monthly equipment downtime, high maintenance costs, and frequent breakdowns of their 40+ piece fleet (excavators, dump trucks, loaders). Their in-house maintenance team lacked specialized expertise.

Challenge

• Reduce equipment downtime to under 5%
• Cut annual maintenance costs by 20%
• Extend the service life of aging mining equipment
• Implement a proactive maintenance program to prevent failures

Mechabro Solution

We delivered a comprehensive fleet maintenance and overhaul solution:

1. Conducted a full fleet audit, identifying high-wear components and maintenance gaps
2. Performed a complete overhaul of 12 high-usage excavators and loaders, including engine rebuilds, hydraulic system upgrades, and undercarriage replacement
3. Implemented a proactive preventive maintenance schedule, with monthly on-site inspections and fluid analysis
4. Trained the client’s in-house maintenance team on advanced equipment care and troubleshooting
5. Established a dedicated spare parts supply chain, reducing lead times for critical components by 70%

Results

• 75% reduction in unplanned downtime, from 20% to 5%
• 28% decrease in annual maintenance costs, saving the client $1.5M per year
• 30% extension in equipment service life, delaying $3M+ in new equipment purchases
• Mining operation achieved 10% higher annual production output, directly boosting revenue