Continuous operation of technological equipment guarantees profit for mining, transportation, or power-generating organizations. High reliability and fault tolerance must be ensured by the Maintenance and Repair (MRO) division, which can be represented either by an in-house repair unit or by service contracts with external contractors.

Today’s reality demands a reassessment of MRO strategy. This is due to the significant presence of imported equipment in technological processes, whose service and spare parts supply have become either impossible or significantly more expensive, time-consuming, and complex to plan. At the same time, domestic production facilities that could replace foreign service providers are engaged in other critical tasks.

For enterprises in the mining and processing industries, metallurgy, and petrochemicals, these challenges justify the need to establish in-house production for manufacturing spare parts, components, and, in the long run, equipment, as well as performing urgent, primarily emergency repairs under their own management.

Our Experience

We have expertise in establishing repair divisions with various functional models:
– In-house repair facilities sufficient to maintain the operation of key technological equipment within the company.
– Production with excess capacity, providing repairs and spare parts both for the company itself and for industry partners or external cooperation services.
– A production center specializing in the reverse engineering of components and assemblies for imported or unsupported domestic equipment, followed by their full-scale manufacturing for in-house use and external sales.

Project “Kazzinc”

We identify the priority range of spare parts for the existing equipment fleet. Each spare part is assigned a weighted coefficient based on its impact on the output of the company’s core production. We evaluate delivery times, the necessity of importing the part, and other critical factors. This allows us to develop a unique risk model for the corporation, assessing how the availability of spare parts for technological equipment used in extraction, raw material processing, and metallurgy affects business profitability and reliability (fault tolerance), depending on the company’s strategic goals.

Taking into account the existing and planned production capacities, as well as the applied technologies of the repair plant, we develop optimal technological processes for manufacturing spare parts using modern metalworking equipment, cutting tools, and fixtures.

Additionally, we conduct a comprehensive assessment of the MRO department and repair units, providing recommendations for improvement. The goal of this work is to establish an optimized business process—from data collection on equipment and repair planning to commissioning of the refurbished unit. A key aspect is the digitalization of this business process, creating an integrated information space for data exchange at every stage. All results are systematically recorded in a digital equipment logbook.

We aim to analyze the complex mechanisms of repair organization and management, sharing our expertise with clients while continuously refining our approach through new challenges. We propose a meeting to discuss the opportunities for establishing and developing spare parts and component production within your company’s corporate framework.