Rio Tinto Fer & Titane

Maintenance cost reduction through optimization of maintenance strategies.

Mandate duration: 12 months
Scope: Material handling equipment and auxiliary services
Pillar engaged: Maintenance strategy optimization

Context

65% reduction in maintenance plan costs

On a continuously operating material handling fleet, the preventive program demanded thousands of hours per year. A large share of those hours went to intrusive, fixed-frequency tasks on components whose failure behaviour no longer justified them.

The problem

What we observed on the floor before the intervention.

Oversized preventive program: fixed frequencies inherited from original OEM recommendations.
Systematic teardowns introducing infant-mortality failures of their own.
No condition data exploited even though the instrumentation already existed.
Maintenance plan cost invisible per equipment, therefore never arbitrated.
Failure history inconsistently coded in the CMMS.

Our solution

The approach deployed with the crews, from diagnosis to autonomy.

01Analysis of dominant failure modes from recoded CMMS history and field interviews.
02Task-by-task review of the preventive plan: tasks without an associated failure mode removed, frequencies adjusted to observed real service life.
03Systematic teardowns shifted to condition-based inspection: vibration, thermography, oil analysis.
04Retained job plans standardized and alert thresholds embedded in the CMMS.
05Gains costed per equipment and presented as a business case validated by operations.