Success Stories
Engineering Reliability Across Every Mine Site
Discover how our maintenance expertise improves equipment uptime, extends asset life, and drives long-term operational success.
Asset Optimization
Ultra-Class Fleet Operational Readiness – Zambia
Challenge
A $450M ultra-class mining fleet required full maintenance readiness during construction and pre-strip, with high risk of commissioning delays, cost overruns, and unclear maintenance accountability.
Solution
Led maintenance establishment across electric rope shovels, rotary drills and Komatsu 860E/960E haul trucks. Developed lifecycle strategies, created work management systems, defined roles, and built full operational budgets.
Results:
- - $450M Fleet Commissioned On Schedule
- - Zero Maintenance Readiness Delays
- - Full Maintenance Operating Model Established
- - Accurate Lifecycle Cost Forecasts from Day One
Maintainance Excellence
National Workforce Uplift & Reliability Transformation – Egypt
Challenge
Low workforce capability, rising downtime and high safety risk in a remote gold mining operation heavily reliant on expatriate leadership.
Solution
Implemented succession planning, rebuild strategies, CMMS transformation, national leadership development, apprenticeships, and major workshop infrastructure
upgrades.
Results:
- - 97% National Leadership Workforce
- - Measurable Reliability & Availability Gains
- - Measurable Reduction in Safety Incidents
- - Fully Modernised Maintenance Workshops
Maintainance Excellence
MARC Contract & OEM Performance Management – Western Australia
Challenge
Large MARC workforce supporting critical production assets required improved availability, cost control and OEM governance.
Solution
Led full MARC management, workforce leadership, OEM contract performance management and KPI enforcement across electric rope shovels and hydraulic excavators.
Results:
- - Stable Production Support on Tier-1 Gold Assets
- - Sustained Availability on 495HD & RH340 Fleets
- - Improved Cost Control & Workforce Performance
Maintainance Excellence
Challenge
Tier-1 miners required independent asset management uplift, CMMS maturity improvement, accurate budget forecasting, tier performance modelling and work
management compliance.
Solution
Delivered tailored asset management uplift programs, SAP work management
coaching, Excellence in Cost Management , equipment replacement strategies, site
audits, and lifecycle modelling.
Results:
- - Improved CMMS Maturity Across Multiple Sites
- - Optimised Replacement & Maintenance Strategies
- - Enhanced Work Management Compliance
- - Improved Tender Accuracy & Cost Competitiveness
- - Reduction in total operating costs
Maintainance Excellence
Heavy Equipment Technical Training & Capability Development – Australia
Challenge
Technicians required rapid competency development on ultra-class haul trucks with
high failure risk and inconsistent training standards.
Solution
Developed and delivered post-trade training programs covering 793C, 793D and 793F
haul trucks with competency-based assessment.
Results:
- - Standardised Ultra-Class Technician Capability
- - Reduced Early-Life Equipment Failures
- - Improved First-Time Fix Rates
Maintainance Excellence
Component Rebuild Program Transformation Delivering Measurable Reliability Gains – East Africa
Challenge
A mining fleet was experiencing chronic component failures, averaging 25–30% premature failures, excessive downtime, and annual replacement costs exceeding USD 8 million. The rebuild workshop had inconsistent standards, weak QA, and limited contamination
control.
Solution
Overhauled the entire rebuild program introducing Component rebuild workshop setup
upgrade, OEM-aligned procedures, precision measurement standards, strict cleanliness controls, and a structured planning and QA workflow. We optimized core recovery, rebuilt component scheduling, and trained the technical team to deliver repeatable, high-quality work.
Results:
- - Within one year, premature failures dropped by over 60%, component life improved by 5,500–6,000 hours, and overall downtime decreased by 22%.
- - The operation saved USD 3.5 million annually through reliable rebuilds instead of reactive replacements—proving the power of disciplined rebuild strategy.
Get In Touch
Let's Discuss Your Asset Management Needs
Phone
Australia Office: +61 474 527 724
Egypt Office: +20 100 736 4603
info@mms-360.com
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