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Publicly Available Case
How BHP reduced outages through risk-based predictive maintenance
Models focus attention on high-risk failure modes, extending PM intervals. The result is fewer unexpected stoppages.
Context
Preventive maintenance was performed too frequently, while critical failures still occurred unexpectedly. This imbalance increased downtime and inefficient use of labor.
Solution
Risk-based monitoring models were introduced to identify failure modes and assess asset health in real time. Maintenance schedules were adjusted dynamically based on risk levels.
Results
The system enabled longer PM intervals and fewer unexpected outages, improving equipment availability and reducing unnecessary maintenance work.
Data Inputs
Telemetry, failure modes, work orders