case Studies

“The visibility of lubrication allows us to not only meet the operating targets, but extend the life of the machine” – Trevor Hyde, Komatsu‘s Regional General Manager, summarising the real-world impact of the GreaseBoss HME Solutions. Learn why Komatsu trusts GreaseBoss for fleet reliability:

The Mangoola team use external contractors to perform manual lubrication tasks and needed visibility and assurance that the greasing was being completed as per the lubrication schedule. The site was successful in: 

The GreaseBoss monitoring system led to the detection of a bypassing injector on the swing box and an incorrect pump timer setting, resulting in estimated cost savings of $70,000 per year and prevented a potential swing box failure.

Ability to detect bypassing injectors & incorrect pump timer setting

Certainty over grease application volumes to critical points

Cost effective critical point and lube system health monitoring

Visibility and control over grease consumption

By installing Endpoint MP2s, the GreaseBoss system immediately identified a critical issue with the lube system pump, preventing a catastrophic failure of over $10,000,000. This installation has successfully ensured proper lubrication and provided visibility to maintenance teams over the automatic lubricator system.

This pilot saved our client around $6,000,000 a year. The GreaseBoss system immediately identified severe under-greasing across all monitored injectors, allowing targeted maintenance and significantly improved truck performance. $250k Cost per kingpin component failure 2 / month failure frequency across the fleet 4/4 injectors were found undergreased $6m/year estimated savings across the fleet The Challenge […]

GreaseBoss Critical Point Monitoring detected that 35 of 40 haul trucks were consistently under-greased, verifying grease delivery at every pump cycle. Within six months the system caught seven A-Frame bearing faults before failure, saving the operation ≈$1.7M in labour and repair costs. Key highlights from the case study: 35/40 Trucks consistently undergreased ≈130 hrs Downtime […]

The customer experienced systemic A-frame bearing failures on their entire haul truck fleet. Without GreaseBoss, both trucks would have been operating with severe under greasing. 2 Haul trucks monitored: CAT 793 & CAT 789 5x System flagged 5x grease volume delivered per cycle vs site spec 250 hrs prevented 250 hrs of operation with no […]

In the first three months after deployment, GreaseBoss Critical Point Monitoring on a Tier 1 gold mine’s SAG mill discovered mistimed pumping, severe under-greasing at the feed end bearings and a failing pinion injector, enabling immediate work orders, closing compliance gaps and preventing a potential mill failure worth AU$25 million in lost production. AU$25M Lost […]

After deploying the GreaseBoss Head Unit on pellet mill roll bearings, the facility replaced operator judgement with flow-verified, RFID-guided greasing at every point. The Maintenance Manager now has visibility over planned vs actual greasing and a 74% year-on-year cut in grease spend, with no recorded downtime, seized rolls, or quality impact. -74% Annual grease spend, […]

$60m Forecasted annual savings 120,000% Return on investment 0 Grease-related bearing failures since installation 52 Endpoint LF units installed The Challenge a major failure every 2 months A Tier 2 coal mine in Queensland was experiencing a major failure occurring every two months, costing the mine $8 – $13.5m per failure in lost production (roughly […]