• Establish root cause for premature failures
• Monitor and schedule replacement of wear parts
• Empower supervisors or foreman to be cost conscious
• Quantify premature failures and exercise warranty claims if necessary
• Employ correct wear solutions for repetitive wear. i.e. use ceramic lining instead of rubber on components exposed to high stream velocity and abrasive index
• Eliminate oil and lube leaks by introducing scheduled maintenance on seals of lube systems (No matter how long it may be required to replace a trivial seal)
• Introduce a reward scheme for exceptional costs savings initiatives

Entails implementation of a holistic planned maintenance schedule for the comprehensive range of your equipment from pump packing or v-belts right through jaw crusher liner or mill gearbox.

• Model maintenance schedule on historical data and equipment life expectancy as per OEM.
• Effectively manage the maintenance TRADE-OFF

Process materials (consumables) are often used as a problem solving tools through overdosage in metallurgical processes, which is merely an expensive way of resolving problems. i.e.

• Carbon in gold process
• Reagents in flotation process
• Steel balls in ball mills
• Ceramic media in tertiary vertical and horizontally stirred mills. i.e. IsaMill, MSD.

.......Here the principle is to refrain from using process materials to offset fundamental flaws like design, operator frailties, unsuitable recipe, equipment size and process bottleneck.

• No Systematic transfer of technical and soft skills from seasoned to new employees
• Lack of operator technical skills development
• Lack of Supervisor process leadership development
• Lack of employee compliance to safety rules compliance tools
• No employee empowerment on ownership and pride over the respective sections