When Innovation Hits the Ground: How TED Transformed Maintenance at HVO

Hunter Valley Operations (HVO) faced daily challenges in maintaining a large fleet of heavy machinery. Tasks such as removing belly guards, servicing track rollers and maintaining hydraulic and cooling systems were proving labour-intensive, physically demanding and putting fitters at high risk of injury. By adopting Nivek’s TED, the mine significantly improved safety, reduced manual handling risks and enhanced operational efficiency.

The Client 

Hunter Valley Operations (HVO) is a leading open-cut mining operator, producing some of the highest quality thermal and semi-soft metallurgical coal in the world. With a substantial fleet, including 34 dozers and over 100 Komatsu 830E haul trucks, the mine’s maintenance team is responsible for keeping these machines operational, performing complex repairs both in the workshop and in the field.

The Challenge – Heavy Lifting Holding Operations Back

HVO’s fitters were undertaking maintenance processes that were physically demanding, inefficient and causing significant downtime on important machines. Many of these tasks involved heavy lifting, hydraulic repairs, cooling system maintenance and ground engagement tool servicing. Removing belly guards and servicing track components required manual lifting and often resulted in machines needing to be transported back to the workshop and causing up to 12 hours of downtime. There was also potential for environmental hazards if hydraulic or cooling fluids spilled during transport. Given the scale and scope of HVO’s operations, improving both safety and efficiency in maintenance processes was a critical objective.

The Solution – From Manual Strain to Mechanical Strength

Introducing TED to the mine site allowed HVO to address their maintenance needs. Removing personnel from hazardous situations and significantly reducing manual handling risks, a single operator could now perform tasks that previously required two people.

TED also dramatically improved HVO’s operational efficiency. In the workshop, belly guard removal time was reduced by around 25%, while in-field maintenance was cut by around twelve hours. Being able to perform in-field repairs also eliminated the need to float machines to the workshop, reducing downtime, streamlining workflows and minimising potential environmental impact from fluid spills. TED’s abilities are also further enhanced by a fully equipped field response trailer, which enables the maintenance team to respond promptly to jobs without the delays associated with transporting equipment.

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