Case study: Partnering for improved machine reliability
A mining customers maintenance strategies were producing good availability results, but to achieve consistency, the...
This is a case study by Joy Global
A mining customer’s maintenance strategies were producing good availability results, but to achieve consistency, the customer wanted better visibility on potential upcoming causes of downtime. In this tough environment, major component failure events need to be controlled to minimize impact against budget, and an enhanced solution was required to improve margins.
Solution Design: Joy Global approached an existing customer about engaging in a trial period where the two would partner through the company’s JoySmart Solutions offering to improve machine reliability and avoid catastrophic failures on major components. The customer agreed to give Joy Global six months to prove the value of the offering at its coal mine in Australia.
The JoySmart team proposed implementation of a newly-developed automated monitoring system that trawls through machine data with the ability to detect any changes in component behavior to predict an onset of failure.
“The key for us was to create an algorithm that was sensitive enough to pick up small changes in component indicators while not creating unnecessary alarms,” said Trevor Griffiths, product performance manager with Joy Global.
The strategy was to build on the existing partnership by employing new technologies and concepts to reach the next level of performance needed in today’s mining industry.
Implementation needed to be quick and effective, with a six month “proof of concept” plan to determine whether the new approach would continue.
The Solution: JoySmart product specialists quickly identified areas of focus that would be prioritized to achieve improved reliability:
• Major Equipment: motors, transmissions, gearing, bearings
• Air Supply
Major equipment monitoring provided the necessary risk management element, whilst air supply and lubrication were identified as systems that had the most impact on reliability.
An engagement strategy was discussed and implemented that had clear lines of communication and accountability. Both companies understood that this needed to be a partnership with common goals and a unified approach.
Using collected sensor data, JoySmart Solutions experts deployed predictive models that could analyze real time sensor data to determine if any of the identified major equipment or systems was starting to drift from “normal” operation. On a daily basis, JoySmart product specialists would intercept any model detections and then report out with a recommended course of action, giving it a priority rating depending on the component type and severity of the detection.
With a system in place, the necessary change in culture was the final hurdle. In the first two months of implementation, a situation arose where an imminent failure condition was detected and reported, but not all recommended steps were followed, resulting in 38 hours of downtime that could have been avoided. Following that incident, team engagement and commitment rose, allowing greater successes to be achieved through the partnership.
The Results: Toward the end of the six-month trial period, the combined machine availabilities hit target eight weeks in a row.
One of the main drivers of change, the need for consistency in machine availability, was now being achieved.
No major equipment failed during the six-month period. The benefits of the partnership were so clear that a planned review of the trial period was deemed unnecessary, and the customer decided to proceed with a long-term partnership. Working together with the JoySmart Solutions team, the customer continues to improve performance every week through new ideas and strategies developed.
Net zero benefits the mining industry and the environment
How do we get the world to net-zero faster?
Emitwise’s founders, Mauro Cozzi, Eduardo Gómez and Ben Peddie, approached a network of more than 100 of the world's largest enterprises and asked their CEOs, CFOs, and sustainability managers the big question: How do we get the world to net-zero faster? The challenge many shared was the lack of timely and accurate emissions data to enable strategic decisions. Companies often relied on annual audits of their carbon footprint for carbon accounting purposes. However, static yearly results were outdated upon publishing.
Emitwise saves companies an average of 260 working days a year by automating their scope 1, 2 and 3 emissions data. With the added benefits of clean audit trails and auto-populated accounting reports in line with GHG Protocol, all at the click of a button. Their easy to use solution enables businesses to quickly identify the carbon hotspots to target, and the precise real-time data empowers teams to remain agile and respond effectively, making achieving those goals possible.
Unique AI Technology
Emitwise’s unique AI technology empowers businesses to automatically measure, report and reduce their carbon footprint across their operations and supply chain, future-proofing companies for a zero-carbon world. It is the only solution that enables companies to fully automate their carbon accounting across all business units and suppliers, therefore liberating them from the drudgery of collecting and processing emissions data.
By using artificial intelligence to precisely measure emissions in real-time, businesses can identify and tackle carbon hotspots swiftly, enabling them to devise a trackable roadmap to net-zero carbon. At the same time, accurate audit trails and auto-populated annual reports ensure that companies comply with international reporting requirements, and align businesses with global climate targets to mitigate risk across their operations and supply chain.
The Oren Marketplace
Environmental management, social license to operate, safety, renewable energy to lower emissions and operational efficiency for mining can be supported by a range of digital solutions enabling dynamic operations. To address these issues, Shell and IBM joined forces to create the Oren Marketplace – the first B2B solutions platform for the mining sector.
With the adoption of many of the digital solutions offered through Oren, mining companies can adapt in real-time to risks or adjust plans ahead of a problem occurring. The goal is a shift towards proactive management as the optimal outcome for all stakeholders – community, shareholders, and employees.
Emitwise was founded with the goal of helping industries across all sectors reduce their carbon footprint. Similarly, Shell aims to become a net-zero emissions energy business by 2050, or sooner, in step with society and its customers. And Oren is focused on offering innovative products and services that can help mining companies track and reduce their emissions.
“Oren is the starting point for how we help our mining customers to de-carbonise,” explains Carol Chen, Global Lubricants Marketing, Vice President, Shell. “It’s our ambition to work with sectors like mining to help them find their own pathway to net-zero emissions through collaboration. The Oren marketplace offers a great opportunity for collaboration between the miners and technology companies that are joining this digital marketplace.”
Emitwise will be showcasing its vision for a net-zero future live from Lisbon at this year’s Web Summit. Bringing together the people and companies redefining the global tech industry, the online event welcomes 100,000+ attendees from around the world to hear from more than 800 speakers and view offerings from 2,500 startups covering a vast range of topics from Data Science and Climate Change to AI and Machine Learning. To find out more and book your ticket visit
Emitwise is one of many solutions providers on the Oren platform seeking to address the pain points and environmental concerns of heavy industries like mining. To discover a range of solutions that can further support your operation’s digital transformation and commitment to sustainability, visit the