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Assets & Maintenance

Common-Cause Screen

Finds unplanned work that repeats across different assets sharing a site and asset type, or consuming the same part, so one root cause is fixed once instead of repaired many times.

Forecast how defects spread (Defect Cascade)
Look-back window3 candidate clusters

Same site and asset type

other at Bengalla Mine (Hunter Valley)

8 unplanned jobs · 2 assets

A$7K recorded cost

Assets: BEN CHPP Product Centrifuge CF-1, BEN Dragline (primary overburden)

  • BEN-WO-263043 · CF-1 vibration trip reset and inspection
  • BEN-WO-263012 · CF-1 vibration trip reset and inspection
  • BEN-WO-263016 · CF-1 vibration trip reset and inspection
  • BEN-WO-263034 · DL-01 hoist brake adjustment
  • BEN-WO-263002 · DL-01 hoist brake adjustment
  • BEN-WO-263015 · DL-01 hoist brake adjustment
  • +2 more
Failure-mode library candidates: Centrifuge basket wear (Wear of the screen bowl causing product moisture rise); Dense medium cyclone apex wear (Ceramic liner wear raising Ep and misplacement); Dragline hoist motor winding failure (Insulation breakdown from thermal ageing); Dragline boom chord cracking (Fatigue cracking at lacing welds under high strain); Dragline drag rope failure (Fatigue and abrasion, broken wires at the drag socket)

Next step: check the shared feed, water chemistry, operating practice, part batch or supplier before repeating like-for-like repairs.

Same site and asset type

conveyor at Bengalla Mine (Hunter Valley)

8 unplanned jobs · 2 assets

A$176K recorded cost

Assets: BEN Overland Product Conveyor, BEN CV-04 Reclaim to Loadout Drive

  • BEN-WO-263051 · CV-02 emergency splice repair
  • BEN-WO-263041 · CV-04 pulley lagging repair
  • BEN-WO-263009 · CV-04 pulley lagging repair
  • BEN-WO-263003 · CV-02 emergency splice repair
  • BEN-WO-263037 · CV-04 pulley lagging repair
  • BEN-WO-263013 · CV-02 emergency splice repair
  • +2 more
Failure-mode library candidates: Drive gearbox overheating (Lubricant degradation or cooler fouling); Pulley lagging wear (Ceramic lagging wear causing slip); Idler bearing seizure (Bearing contamination and seizure); Belt rip (Tramp metal or chute damage slitting the belt); Belt splice failure (Cord pull-out at splice, fatigue)

Next step: check the shared feed, water chemistry, operating practice, part batch or supplier before repeating like-for-like repairs.

Same site and asset type

crusher at Bengalla Mine (Hunter Valley)

7 unplanned jobs · 2 assets

A$8K recorded cost

Assets: BEN Secondary Sizer SZ-201, BEN Primary Sizer

  • BEN-WO-263032 · SZ-201 coupling replacement
  • BEN-WO-263033 · Primary sizer tramp-metal removal and chute repair
  • BEN-WO-263026 · SZ-201 coupling replacement
  • BEN-WO-263035 · SZ-201 coupling replacement
  • BEN-WO-263017 · SZ-201 coupling replacement
  • BEN-WO-263014 · Primary sizer tramp-metal removal and chute repair
  • +1 more
Failure-mode library candidates: Sizer gearbox bearing failure (Bearing fatigue, lubrication breakdown); Sizer tooth and segment wear (Abrasive wear reducing product sizing)

Next step: check the shared feed, water chemistry, operating practice, part batch or supplier before repeating like-for-like repairs.

Screening rule: at least 3 corrective or emergency work orders across at least 2 distinct assets within the window, grouped by site and asset type or by consumed part number. Clusters are candidates for root-cause analysis, not confirmed common causes. Limits: 1,000 most recent work orders.