- Eliminate costly grease-related bearing failures and associated production losses.
- Achieve exceptional ROI with $60m in forecasted annual savings from a $50k investment.
- Ensure precise lubrication with real-time data comparing planned versus actual grease volumes.
- Proactively detect equipment issues like failing autolube pumps before they cause major damage.
$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 $10m per failure).
Incorrect lubrication was identified as the root cause of most of these failures. All of the sizers had been installed with an automatic lubrication system by the OEM, which was tuned and managed by the OEM.
$8 – $13.5m
LOST PRODUCTION PER FAILURE
every 2 months
MAJOR FAILURE FREQUENCY
The Solution
CRITICAL POINT MONITORING ON BOTH CRUSHING TRAINS
GreaseBoss implemented the Critical Point Monitoring solution, installing 52 Endpoint LF units on the two crushing trains.
This solution provided near real-time lubrication volume data, allowing for immediate comparison of planned vs actual greasing volumes to the engineering design.
1
52 Endpoint LF on 2 crushing trains
Endpoint LF units fitted to every critical grease point
2
Near real-time lubrication volume data
allowing for immediate comparison of planned vs actual greasing volumes to the engineering design.
Key findings
reduce annual grease spend by 74% year-over-year
Return on investment
$60m saved annually from a $50,000 investment
FORECASTED SAVINGS
$60m PER YEAR
INVESTMENT
$50,000
ROI