Optimizing Maintenance Strategy for a Longwall Shearer in Coal Mining

In the mining industry, equipment reliability is essential for both safety and productivity. A global mining company faced the challenge of developing a preventive maintenance strategy for a newly installed longwall shearer at one of its underground coal mines. The previous mining system had been in operation for decades, and the organization wanted to ensure the new equipment started its lifecycle with a robust, effective maintenance program.

The client’s goal was to avoid repeating past inefficiencies, where previous reliability studies had taken too long and did not result in actionable preventive maintenance tasks. Instead, they needed a comprehensive program built quickly, using vendor manuals, proven methodologies, and input from on-site personnel.

The process began with building the equipment hierarchy for the new shearer and applying the vendor’s recommended maintenance strategy. Tasks were reviewed, refined, and grouped into structured preventive maintenance (PM) programs. This ensured that all relevant failure modes were addressed while eliminating duplicate or non-value-adding activities.

Electrical, mechanical, and operations teams collaborated throughout the review, providing practical input and confirming that strategies were aligned with day-to-day realities in the mine. Commissioning schedules were produced, ensuring that preventive maintenance activities could begin immediately as the new system came online.

By focusing on strategy management and optimization, the company established a foundation for improved reliability, maintainability, and fault detection—positioning the new longwall shearer for long-term operational success.

Download the full case study to learn how a mining company developed and implemented an optimized maintenance strategy for a newly installed shearer on time and within budget.