How to plan a minesite shutdown that finishes on time

A shutdown is one of the few times you can get major maintenance done on critical equipment. It’s also expensive. Every hour over schedule is lost production.

Our shutdown crews work across the Bowen Basin, and the shutdowns that run smoothly almost always share the same groundwork. Here’s what we recommend.

Heavy equipment working at a Bowen Basin coal mine site

1. Lock in the scope early

List every task you want done, then rank them: must-do, should-do and nice-to-have. Use oil analysis, inspection reports and operator feedback to build the list. A clear scope stops jobs creeping in on the day.

2. Get parts on site before the shutdown starts

Parts delays are the most common reason shutdowns overrun. Order early, confirm lead times, and have critical components staged and checked before crews arrive. It’s worth holding spares for wear items you are likely to find once machines are opened up.

Final drive components wrapped and staged on site before a shutdown

3. Size the crew to the job

Too few people and the schedule slips. Too many and they get in each other’s way. Match trades to tasks: diesel fitters, boilermakers, auto electricians and trade assistants, with clear supervision.

4. Sort compliance and inductions in advance

Make sure every crew member has site inductions, tickets and medicals completed before day one. Check that vehicles and equipment coming on site meet your site’s compliance requirements.

5. Plan the logistics

Work out equipment movements, cranage, lighting towers, tooling and accommodation ahead of time. Know what’s being transported in and out, and when.

Crane lifting a final drive during a Bowen Basin shutdown

6. Run a daily check-in

A short start-of-shift meeting keeps everyone aligned on progress, safety and any changes in scope. Problems found early are problems solved early.

Shutdown crew lifting a heavy component with chain blocks on fixed plant

7. Review afterwards

Record what went well and what didn’t. That record makes the next shutdown faster and cheaper.

Shutdown support from Mackay

KBX Mechanical provides minesite shutdown crews along with the support around them: labour hire, minesite compliance fit-outs, transport and logistics and parts supply. Recent shutdown work has included final drive change-outs on CAT 785C water trucks and heavy component lifts on fixed plant, with our crews working alongside site teams to get equipment back online on schedule.

KBX shutdown crew working on scaffolding at a coal handling plant

Planning a shutdown? Get in touch or call 0457 157 795 to talk through your scope.