Improving safety while decreasing maintenance costs, one Komatsu haul truck at a time.

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Mining operations in Australia face an array of challenges when conducting routine maintenance on their fleet, among them is using thermal lancing practices to cut through worn components for removal. 

Thermal lancing is a dangerous step to have in any maintenance procedure. The molten metal created is often projected from the cutting zone at high velocity, posing risks such as severe burns, eye injuries, general fire hazards, and toxic fume emissions. On top of the safety concerns, thermal lancing incurs considerable costs due to the inherent risks associated with the process. 

Unplanned downtime resulting from accidents or equipment failures during thermal lancing operations leads to productivity losses and financial setbacks. Compliance with environmental regulations, legal liabilities, and the replacement of damaged components further contribute to the overall cost.  

Additionally, continuous improvement efforts to enhance safety practices and risk mitigation strategies involve ongoing financial commitments. While thermal lancing is a valuable tool, its costliness underscores the importance of careful management and prioritisation of safety in mining maintenance operations.

One of the critical challenges in mining maintenance revolves around the need to remove seized or stuck components, traditionally addressed by resorting to thermal lancing. However, this method exposes workers to risks such as lung damage, asthma, hearing loss, and extreme heat exposure. In response, Geographe introduced the Colleted Pin Assembly (CPA), which eliminates the need for thermal lancing for pin changeouts on Komatsu 830e & 930e haul trucks.

The CPA incorporates a tapered collet system that creates a self-wedging effect between the pin and frame bores, effectively eliminating pin seizures. More than just a safety upgrade, the CPA translates into significant cost savings. The removal of thermal lancing from the equation means reduced expenses related to equipment, labour, and potential damage to adjacent equipment. Moreover, by addressing the root cause of seized components, the CPA contributes to an extended equipment lifespan, reducing overall maintenance and replacement costs.

Geographe's commitment to safety has been rigorously tested and proven in the field. Successful trials of the CPA on an active mine site showcased its flawless operation for over 12,000 hours. From there, Geographe optimised the product and developed an installation & removal tooling kit tailored to suit each application.

Understanding the continued importance of mine site safety, efficiency, and increased machine longevity to miners and off-site repairers, Geographe’s CPA Tooling kit provides a lightweight design. This design aims to minimise handling risks and deviations from safe work practices while facilitating the installation and removal. By making maintenance more efficient, the CPA reduces machine downtime, contributing to enhanced productivity.

Geographe's Colleted Pin Assembly (CPA) is more than a solution to a specific mining challenge; it represents a shift in safety and cost-effective efficiency within the Australian mining industry. By eliminating the need for thermal lancing and introducing innovative manufacturing practices, Geographe is not just meeting industry standards; it is setting new benchmarks. As the mining sector in Australia continues to evolve, Geographe's commitment to providing safer, more efficient maintenance solutions ensures that it remains at the forefront of industry innovation.