Today
Replacement follows the calendar
- Parts are changed on fixed schedules or after visible failure.
- Usage and failure history stay mostly retrospective.
- The same interval may be applied across different duties and rock conditions.
Bucket teeth don't fail on a calendar.Why replace them on one?
Abrasive rock wears bucket teeth and other high-wear parts at different rates by duty cycle and rock domain. Fixed intervals waste life or leave machines exposed. INSUS uses usage and maintenance history you already keep to estimate failure risk and recommend a replacement window for the team to review.
01
Wear follows usage, not the calendar.
02
Rock domain and duty cycle change the rate.
03
Maintenance stays with the team.
The problem
Abrasive wear is variablereplacement schedules often are not.
Loaders and excavators in abrasive rock see wear that shifts with hours, material and how the machine is worked. Bucket teeth and similar parts are still often replaced on a fixed interval or after visible failure. Without a usage-based view, teams struggle to tell whether a part still has life or is approaching a failure risk that will stop production between planned windows.
01Abrasive wear
02Duty-cycle variability
03Unplanned failure
- 01Abrasive wear
- 02Duty-cycle variability
- 03Unplanned failure
The shift
From a fixed intervalto usage-based risk.
The maintenance team stays in charge of what gets replaced and when. What changes is whether timing is informed by how that machine has actually been used on this quarry.
With INSUS
Plan around predicted wear risk
- Timing reflects the machine's actual usage history.
- Risk estimates can include rock domain and duty cycle where those records exist.
- Teams review recommended windows against planned maintenance and production.
How it works
From usage historyto a maintenance recommendation.
This fits Predictive Maintenance as advisory wear timing for high-wear mobile equipment. Day one is decision support: no automatic work orders, shutdowns or control-system writes.
Connect
Bring maintenance and usage history together
Read-only links to CMMS or maintenance records, operating-hour logs and, where available, rock-domain or duty-cycle data. Existing telematics can be added when already in place.
Understand
Learn how usage drives wear
Learn how hours, rock conditions and duty cycle have related to replacement and failure timing on this quarry's own history.
Predict
Estimate remaining useful life
For a defined wear part, estimate remaining life and failure risk from that machine's actual usage pattern and relevant operating conditions.
Advise
Recommend a maintenance window
Surface a replacement or reconditioning window for review so the team can align intervention with planned maintenance and production. No automatic work-order creation.
Verify
Check predictions against outcomes
Compare recommended windows with actual wear condition and failures, then recalibrate using the quarry's growing maintenance history.
Getting started
Start with one equipment classand the records you already keep.
For aggregates operations with CMMS and usage history on high-wear loaders or excavators. Delivered through Predictive Maintenance. Expert Services can help with discovery and pilot validation. No new sensors are assumed for the baseline; existing telematics improve granularity when already available.
- What we need. Maintenance or CMMS records, equipment usage-hour logs and, where available, rock-domain or duty-cycle information.
- What you see first. Estimated remaining useful life and failure risk for defined wear parts, with recommended windows for maintenance review.
- How it grows. After validation on one equipment class, extend across additional machines and part types as outcomes support it.
Related for aggregates
Other aggregatesstarting points
Wear-part timing sits beside blast feed quality and crusher circuit balance on the same quarry.
- 01Aggregates Blast Fragmentation OptimizationRecommend blast design adjustments from blast and crusher history so fragmentation matches what the primary circuit needs.
- 02Aggregates Crusher Circuit OptimizationRecommend crusher settings to balance throughput, energy and product gradation from plant production and quality data.
- 03Aggregates industryThe wider picture for quarry crushing, screening, inventory and maintenance.
Questions aggregates maintenance teams ask us
Fixed replacement intervals often waste usable part life or leave machines exposed to abrasive wear failure. This use case estimates failure risk from usage and maintenance history so teams can plan replacement before an avoidable stop.
CMMS or maintenance records, equipment usage-hour logs and, where available, rock-domain or duty-cycle information. Existing telematics can be included when already available.
No for the baseline. The pilot starts from maintenance and usage records. Existing telematics or wear instrumentation can improve granularity when already on site.
High-wear parts on quarry loaders and excavators, such as bucket teeth. Other classes need enough historical maintenance data to assess fit.
No. It is advisory decision support. The maintenance team reviews recommendations and decides when to replace or recondition. There is no closed-loop control.
No. This use case focuses on wear prediction and maintenance timing. Crusher setpoints and blast design are separate aggregates use cases.
Through Predictive Maintenance as advisory wear timing for aggregates mobile equipment. Expert Services can support discovery, data readiness and pilot validation against the quarry's own baseline.
Aggregates · Equipment maintenance
Replace when risk rises not when the calendar says so.
Turn maintenance and usage history into a forward-looking wear view for one equipment class. Your team stays in control of what gets replaced and when.