When a mining truck is out of service, it can cost an operation millions of dollars. The impact is significant when one or more trucks come to a grinding halt because a crucial component is no longer manufactured by the original equipment manufacturer (OEM).
This was the predicament of a South American mining company serviced by UHCO CHRISTENSEN, a Chilean-based mining equipment parts and maintenance specialist.
Fortunately, Spuncast’s centrifugal casting technology provided a timely and effective solution.
CHALLENGE: Discontinued parts, disrupted operations
UHCO CHRISTENSEN prides itself on keeping its clients’ mining machines operational, but when a critical component for one of its larger client’s trucks became unavailable, it threw a wrench into its plans.
With a crucial rear suspension cylinder no longer available from the OEM, their client faced the prospect of a halted operation.
The impact of downtime
When a mining truck is out of commission, the repercussions are far-reaching:
- Halt in Production: A single truck breakdown can disrupt the entire mining operation, leading to substantial revenue loss.
- Financial Strain: Downtime results in direct financial losses due to lost production and potential penalties for missed delivery targets.
- Labor Costs: Idle workers and overtime for repairs contribute to increased operational expenses.
- Safety Risks: Malfunctioning equipment can pose safety hazards to workers.
But there’s an even bigger problem. OEMs of large mining trucks and vehicles discontinue parts after a certain amount of time, often a decade or two, making it nearly impossible to find replacement parts.
According to Joe Ferch, Business Development Manager for Spuncast, discontinued parts are a common and growing headache, especially for older equipment. Mining operations often rely on machinery with long lifespans stretching back decades.
These older pieces of equipment are starting to experience more and more issues. A recent report by Grand View Research underscores the growing demand for mining equipment aftermarket parts, projected to reach $284.93 billion by 2025.
This leaves mining equipment maintenance companies like UHCO CHRISTENSEN needing more aftermarket part options to keep their existing infrastructure operational.
SOLUTION: Custom-made parts with centrifugal casting
Spuncast successfully manufactured a replacement rear suspension cylinder for UHCO CHRISTENSEN’s client. The new part matched the original specifications and exceeded expectations in terms of durability and performance.
“In this case, the discontinued part was a custom-made component within a larger assembly, the rear suspension cylinder,” Ferch explained. Spuncast manufactured a replacement casing using high-grade stainless steel that was customized to meet the demanding needs of the mining applications.
By rapidly rotating molten metal within a mold, Spuncast’s centrifugal casting process produces parts with superior strength, density, and uniformity compared to traditional casting methods.
For the mining industry, centrifugal casting provides several advantages:
- Material Versatility: Suitable for a wide range of metals, including high-grade stainless steel, essential for mining equipment.
- Enhanced Durability: Parts created through centrifugal casting exhibit exceptional resistance to wear and tear, extending their lifespan.
- Precision Manufacturing: The process allows for precise control over dimensions and tolerances, ensuring accurate replacements.
- Cost-Effectiveness: While the initial investment in molds may be higher, the long-term cost savings often outweigh upfront expenses.
RESULTS: Beyond saving the day
The impact of centrifugal casting went beyond getting their client’s truck back up and running quickly. It also resulted in:
- Reduced Downtime: Every minute a truck is down costs money. Spuncast’s solution minimized downtime, saving significant money for UHCO CHRISTENSEN’s client.
- Cost-Effectiveness: Compared to buying a new truck, centrifugal casting was a fraction of the price.
- Long-Term Advantages: Thinking ahead, UHCO CHRISTENSEN kept several spare casings on hand, preventing future disruptions and ensuring smooth operations.
“They come back every single year, and they order a number of replacement parts that they actually keep in stock themselves so that when their trucks go down, they’ve got what they need on hand,” says Ferch.
Keeping industrial machines moving
The challenges posed by discontinued parts extend beyond the mining industry. Manufacturers in sectors such as agriculture, construction, and energy often face similar issues.
The growing demand for aftermarket parts, coupled with the challenges of out-of-stock or discontinued parts, highlights the need for innovative solutions.
Centrifugal casting stands out as a powerful method to tackle these challenges. This process produces high-quality, durable replacement components, helping to minimize downtime, reduce costs, and improve overall operational efficiency.
