Mining Reliability : How ACOEM's MV-x Helped VALE Save 7.8 MUS$

Country: Brazil
Application: Mining, specifically focusing on equipment reliability and predictive maintenance for mining operations.
Customer Name: VALE (Car dumper site)

EXECUTIVE SUMMARY

ACOEM’s advanced predictive maintenance solutions, including the MV-X system, have helped VALE, one of the world’s largest mining companies, overcome significant operational challenges at its car dumper site. By implementing ACOEM’s cutting-edge diagnostic tools, such as the MV-X, and expert analysis, VALE was able to detect critical equipment faults early, preventing costly failures and downtime. In just 18 months, ACOEM’s solution, powered by the MV-X, saved VALE 7.8 MUS$ in potential production losses and avoided the loss of 720 wagons of material. This success not only improved operational efficiency but also reinforced VALE’s proactive, data-driven approach to maintenance, setting a new benchmark for reliability in the mining industry.

The Challenge

VALE, one of the largest mining companies in the world, faced significant challenges in ensuring the reliability of their operations at the car dumpers site. Frequent equipment faults posed a risk to operational efficiency, leading to potential production delays and substantial financial losses.
The consequences of undetected faults included costly repairs, unplanned downtime, and the risk of losing entire shipments. These challenges directly impacted their production schedule and profitability.

The Acoem Solution

To address these challenges, VALE implemented ACOEM’s advanced predictive maintenance solutions, including the MVX — a condition monitoring system that played a crucial role in detecting equipment failures. By leveraging cutting-edge diagnostic technology and expert analysis, ACOEM provided VALE with the tools needed to proactively detect equipment issues and avoid costly failures.

The MVX enabled VALE to monitor equipment conditions in real-time, analyze collected data, and identify anomalies well before they impacted operations. This solution was key in preventing critical failures by enabling quick, targeted interventions.

The Results

After integrating ACOEM’s solution over 18 months, the results were remarkable:

16 faults detected: Preventing critical failures and ensuring equipment reliability.
8.8 shipments saved: Equivalent to avoiding the loss of 720 wagons of materials.
7.8 MUS$ in production losses avoided: A significant financial impact on VALE’s operations.

The Impact

Beyond the immediate results, ACOEM’s solution empowered VALE to adopt a more proactive and data-driven approach to maintenance, strengthening their overall operational strategy. The long-term relationship established between VALE and ACOEM has positioned them as a benchmark for reliability in the mining sector.