CASE STUDY

How a global mining operator built its crusher FMECA 8.4x faster, cut unscheduled crusher downtime by 21.3%, and resolved 3 repeat events.

INDUSTRY
Mining

SYSTEM
Crusher circuit

SCOPE
FMECA and RCM

INTEGRATIONS
SAP PM, Maximo, OSIsoft

ENGAGEMENT
3 months

Bucket-wheel excavator working an open-pit mine

Automated work order processing and FMECA updates were two major benefits of Tacit AI. It helped us find and resolve 3 repeat events and hours of downtime.

Maintenance Lead
Global Mining Operator

CHALLENGE

One hour of primary crusher downtime costs up to $1m. A FMECA prevents it, but a traditional one takes more than a month per system and produces 1,000+ Excel rows that are hard to turn into preventive tasks. The evidence sits in work orders, dispatch notes and manuals across 3,000 to 20,000+ maintainable items, and staff tenure is short.

One metal jam: 30 hours down at $55k an hour
Tramp metal, liner wear, lube issues and screen blinding
HPGRs underfed by 10 to 25% against nameplate
Work orders and dispatch notes without failure-mode fields
More than a month per FMECA, 1,000+ Excel rows

SOLUTION

A crusher FMECA in weeks

  • Work orders, user manuals and procedures loaded from the CMMS and SharePoint into the operator’s private cloud.
  • Asset hierarchies and functional models built in week 1.
  • Risk and criticality estimated and a failure mode database built.
  • Initial FMECA on the gyratory crusher by week 4, with mitigating tasks, PRTs and work instructions.
Tacit AI FMECA and RCM workspace with failure modes and mitigating tasks

A FMECA that keeps learning

  • From week 8, the FMECA scales across similar equipment and down into each system.
  • Every engineer interaction teaches the model to identify bad actors before they repeat.
  • From week 16, risk is recalculated as operating conditions change.
  • PM updates are proposed as throughput targets shift.
Tacit AI work order view linking failure reports to FMECA rows

RESULTS

8.4x
Faster FMECA, 88.1% less time to create and update

21.3%
Less unscheduled crusher downtime, about 26 hours a year

3.2x
Faster PRTs and PMIs, 68.2% less time to create

We tested Tacit AI to build an FMEA for a critical screener. We gave it troubleshooting and maintenance PDFs, a BOM in Excel and a few sentences of context. The output was an 80-90% ready FMEA with mitigating tasks, work instructions and clear AI reasoning that our engineers could quickly adapt and load into our reliability system.

Reliability Lead
Global Mining Operator, Crusher Circuit

See what Tacit AI delivers for your team.

Pick one critical system. First results in 3 weeks. Clear gates at every step.

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