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Roller Failure and Downtime Significantly Reduced at Yandi

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Yandi contracted CPS to assess the situation of their steel rollers and implement a strategy to solve the increased downtime and idler failures that the site was experiencing. Upon evaluation, the CPS team suggested to implement a composite bulk changeout—installing Yeloroll HD Carry rollers, Polyurethane Sleeve Impact rollers and Polyurethane Ring Returns.

The Challenge

From 2016 to 2019, Yandi has been experiencing increased downtime due to idler failures, as their current steel rollers were starting to reach their end of life, therefore negatively impacting productivity and performance.

Due to these frequent unplanned shutdowns, their steel rollers needed to be replaced.

The Solution

The priority locations for the bulk idler changeout were previously based on hotspot locations of high-frequency failures. The implementation of composite idlers began in 2020, and around 50% of Yeloroll HDPE carry and return idlers and polyurethane Sleeve Impact rollers were installed in the same year.

Upon completion of the project, the CPS team installed a total of 4,561 Yeloroll HD carry rollers, 344 Polyurethane Sleeve Impact rollers, and 880 Polyurethane Ring Returns.

Failure trend started to decrease since the implementation of the bulk changeout strategy.

Two years on and the bulk changeout strategy complete, roller failures are less than 25% of the 2016-2019 levels, and loss of tonnes has decreased to only 35,000 tonnes, down from 177,000.