CMMS for Mining

Mining plants run two very different asset populations under one roof — fixed process equipment like crushers, screens, mills and conveyors, and a mobile fleet that moves ore, waste and materials across the site. Most maintenance tools pick one and bolt the other on later. AssetAI keeps both in a single asset registry so breakdowns, PM, spares, AMC and analytics work the same way whether the asset sits on a foundation or drives on tyres.

One schedule form, two ways to trigger a PM

Fixed plant tends to run on calendar time; mobile equipment wears by usage. AssetAI's PM schedule form takes both without forcing a workaround:

• Time-based PM for crushers, screens and mills — due dates driven by the calendar.
• Usage/meter-based PM for loaders, dumpers and other mobile assets — due dates driven by run-hours, cycles or km.
• Meter readings can be logged from the internal screen, a QR scan (with photo OCR filling the value), a WhatsApp command, or via API — and a reading lower than the last one is rejected outright, so a fat-fingered entry can't silently reset a maintenance clock.

For a subset of critical assets you can also define a condition-based maintenance type — a monitored parameter (say, vibration in mm/s) with an alarm threshold that raises a PdM work order when crossed. This is manually entered rather than fed by a live sensor stream, so it suits sites that spot-check with a handheld meter rather than run continuous monitoring — worth understanding before you assume it's telemetry-driven; see what a CMMS does and doesn't cover.

Built for the conditions mine sites actually have

Weak connectivity, contractor labour and cost-heavy repairs shape how mining maintenance software needs to behave, not just what features it lists:

• The mobile PWA keeps a last-good copy of shop-floor pages and queues offline breakdown reports for sync later — relevant when a crusher house or conveyor gallery sits outside reliable signal.
• QR-scan breakdown reporting needs only a name and company PIN — no login, no app install — so contractors and operators on rotating shifts can log a stoppage without onboarding friction.
• Emergency-severity breakdowns skip the approval step and raise the work order immediately, which matters when a stopped conveyor halts the entire line rather than one machine.
• AMC and vendor data are held per asset, with coverage status — warranty, AMC or expired — auto-stamped on every service call in that precedence order, so repair cost and vendor choice are routed correctly without someone checking a contract folder first.

Where the maintenance budget is actually going

Mining plants lose money in concentrated places — a handful of chronically underperforming crushers or conveyor sections, and a handful of assets past their useful economic life. Two views are built specifically to surface that:

• A downtime cost Pareto ranks the top 8 assets by downtime cost per hour × downtime hours, pointing straight at the worst bottleneck section instead of an average across the plant.
• An RRR (Repair/Review/Replace) score, computed per asset from work-order cost, failure trend, downtime cost, age and warranty status, shows the full reasoning as readable lines — not just a verdict — so a maintenance manager can defend a replace decision to finance with the underlying numbers.

Both depend on BM/CM work orders that can't be closed without a recorded failure cause and remedy — a rule enforced in code, which is what makes a Pareto on crushers or conveyors trustworthy after a few months rather than a rough guess. If you're building the case for this kind of instrumentation, the OEE explainer and background on TPM are useful starting points, and our industries overview shows how the same registry model applies elsewhere in India's asset-heavy sectors, per IBEF's industry data.

Mining sites run maintenance under conditions that break most software assumptions: patchy network coverage, contractors and operators who won't install an app, and a mix of safety-critical and routine failures that all land in the same work-order queue. AssetAI is built around that reality rather than around a clean office network and a fixed workforce.

Reporting a breakdown without a login

A crusher operator or a contractor's rigger is rarely going to install an app, remember a password, or fill in a long form before a stopped conveyor gets attention. AssetAI's breakdown reporting works off a QR code stuck on the asset:

• Scan the QR code, enter name and company PIN — no login, no app install.
• The report reaches the maintenance team immediately; emergency-severity breakdowns skip the approval step entirely and raise the work order straight away, which matters when a stopped conveyor halts the whole line.
• On sites with weak signal, the mobile PWA keeps a last-good copy of shop-floor pages and queues offline breakdown captures, syncing them once connectivity returns instead of losing the report.

Closing the loop matters as much as opening it. A breakdown or corrective work order can't be marked complete without a recorded failure cause and failure remedy — that's enforced in code, not left to discipline — which is what makes a failure Pareto on crushers and conveyors trustworthy months later instead of a guess.

Coverage and vendor routing that don't rely on memory

Mining plants run a lot of AMC and warranty coverage across process and mobile assets, and knowing which applies at the moment a repair is raised is usually tribal knowledge. AssetAI stamps this automatically:

• Every service call auto-shows coverage status — in warranty, under AMC, expired, or none recorded — using a fixed precedence so there's no ambiguity when multiple records exist.
• The correct vendor is pre-filled based on that coverage, so repair cost and vendor choice route themselves instead of depending on someone checking a spreadsheet.
• Downtime cost per asset (downtime cost/hour × downtime hours) rolls up into a Pareto of the top 8 assets, surfacing the section that's actually draining the budget — often not the asset with the most work orders, but the one with the longest stoppages.

This is the same asset registry and analytics layer described under features, applied specifically to the fixed-plus-mobile mix a mine site carries.

Deciding what to repair, review, or replace

Old crushers and ageing mobile fleet accumulate cost in ways that are hard to see work-order by work-order. AssetAI's RRR (Repair/Review/Replace) score pulls together work-order cost, failure trend, downtime cost, age and warranty status per asset — and shows the reasoning as readable lines, not just a verdict, so a maintenance planner can see why an asset was flagged rather than take the score on faith.

That combination of readable scoring and a real failure Pareto is the kind of groundwork most TPM programs need before they can talk credibly about OEE — see our OEE explainer for how "units lost" gets calculated from a rated-output figure. If you're evaluating a CMMS for a mine site for the first time, the what-is-a-CMMS primer and the pricing page are a reasonable place to start before booking a walkthrough.