Ageing Equipment & Bad Actors

Preserve and maintain ageing equipment through enhanced maintenance and skilled usage
Preserve and maintain ageing equipment through enhanced maintenance and skilled usage


Preserve and maintain ageing equipment through enhanced maintenance and skilled usage

Ageing equipment is more prone to mechanical failures, increasing the risk of accidents and injuries for workers. This equipment will require more frequent maintenance and repairs, leading to increased downtime, maintenance costs and decreased operational efficiency. Additionally, when equipment bad actors are not recognized and managed, fleet performance suffers immediately. Like a cut-off grade for the ore body, ageing (or poorly maintained) equipment reaches a point where it is no longer profitable to operate.

In addition to the individual piece of equipment, these bad-actor units reduce fleet performance to the lowest common denominator by slowing the mining cycle. Furthermore, older equipment often lacks the latest technology and replacement parts become less available or cost prohibitive.

As equipment ages, the necessary training for operators must be available to understand the nuances of operating such equipment. Implementing predictive maintenance programs that utilize data analytics and sensors can also help to identify potential equipment failures before they occur, reducing repair costs when equipment ceases to function as well as enhancing safety for workers.

Key Client Challenges:

  1. How can we extend the lifespan of our ageing equipment without compromising safety and efficiency?
  2. What are the key indicators of equipment deterioration or potential failures, and how can we monitor them effectively?
  3. What modernization and upgrade options are available for our ageing equipment, and what is the return on investment for such improvements?
  4. How can we implement predictive maintenance strategies to reduce unplanned downtime and maintenance costs?
  5. What training and skill development programs can we offer our workforce to ensure safe and responsible equipment operation and maintenance?
  6. What safety protocols and measures can we implement to mitigate the risks associated with bad actors operating machinery irresponsibly?
  7. How can we enhance security measures to prevent theft, vandalism, and unauthorized access to equipment and facilities?

With ageing equipment, promoting a strong safety culture within the organization, including safety protocols, reporting mechanisms, and incentives for responsible behavior can help to mitigate risks associated. Additionally, by transitioning to newer equipment gradually and leveraging data analytics, predictive maintenance and artificial intelligence, operators can more effectively detect unusual patterns in equipment usage, staving off accidents and irresponsible equipment usage.

Our experts at Unison Mining can assist your team with developing the processes, systems and KPIs needed to reinforce this safety culture in a sustainable way. With new ways of working incentivized at every organizational level, your team is set up to better maintain equipment, with more accountability and responsibility.

Lacking data to validate or support key business decisions

Lack of knowledge to define a cohesive business or data strategy

Low speed to market and trouble adapting quickly to customer and market needs

High operational costs due to lengthy data processing times


Maintenance Strategy

Define a tailor-made maintenance strategy to suit the needs and equipment of your mine
Read More

Wrench Time Optimization

Explore the behavior changes needed to optimize wrench time and maintenance productivity
Read More

Response Time Practices

Reduce response time and establish and communicate comprehensive practices for equipment accidents or near-misses
Read More

Work Order Systems Enhancements

Optimize maintenance workflows to fully utilize existing work order systems and technology
Read More

Equipment Aging & Bad Actors

Identify bad actor equipment faster to avoid accidents and downtime due to aging equipment
Read More

Spares & Tools Management

Systemize the procurement and storage of spare parts and tools to hedge against unforeseen downtime
Read More

Ready Backlog

Minimize delays in returning idle equipment to service by allocating a ready backlog of maintenance personnel and kitted materials
Read More

Kitting & Critical Path

Consolidate parts, materials, and tools prior to a maintenance event to eliminate lost wrench time
Read More

Subtask Time Estimation

Estimate sub-tasks more accurately to ensure the total hours estimated will be met or reduced.
Read More



Our mining experts have experienced first-hand the day-to-day complexities and issues that arise at the mining face, giving them a higher level of understanding and insight to meet your challenges.

Practical Solutions

By implementing level-appropriate transformation tools, our behavioral and cultural change methodologies, data management, and analytics, our goal is to create a sustainable and positive impact on your mining operations.


We go beyond strategy to offer a direct and measurable approach to success. Our commitment extends to delivering real business outcomes and helping your team sustain those changes for the long haul.

Maintain and operate ageing equipment safely while transitioning gradually to modern machinery.

Seize this opportunity before you leave!

Ready to take your operations to the next level?

Simply fill out the form to schedule a consultation with our expert consultants