Conveyor belt maintenance is one of the most critical activities in mining operations. Long intervention times, ergonomic risks, and high labor consumption directly impact indicators such as MTTR, physical availability (PA), and operating cost.
In this context, Winners Industrial implemented the use of the Screw Jack® within Vale’s Shipping Yard Maintenance Management in Carajás.
The result: significant gains in safety, productivity, and cost reduction.
Challenge: high physical effort and low efficiency in idler replacement
Before the tool was implemented, the team used a 100% manual device to lift the belt.
Main issues identified:
- 94 to 112 repetitive movements per idler
- Up to 180 seconds for lifting
- Replacement of only 1 idler per lift
- Ergonomic risks classified as HIGH and VERY HIGH
- Risk of hand and finger pinch points
- High employee exposure time
Solution: Screw Jack® driven by a cordless drill/driver
The Winners Industrial Screw Jack® brought a structural change to the process. The tool became part of the operation’s standardized procedure.
Main technical improvements:
- Cordless drill/driver actuation (elimination of manual effort)
- Reduction in lifting time from 180 seconds to 25 seconds
- Ability to release up to 18 idlers with a single lift
- Elimination of repetitive movements
- Reduction of pinch-point risk
Proven operational results
86%
reduction in
lifting time
From 180 seconds per idler
To 25 seconds per idler
50%
Increase in average
workforce availability
Historical trend of indicators over the last 3 months
R$ 61 thousand
in average
savings per team
Reduction from 8 to 4 mechanics for the activity
Improvement in indicators
After implementation:
- Improvement in AMS and AMC indicators
- Positive impact on PA (Physical Availability)
- Reduction in MTTR
Impact on safety and ergonomics
The implementation eliminated:
- Muscle overload from repetitive movements
- Excessive physical effort
- Medium risks converted to low risk in the safety matrix
The tool significantly reduced employees’ exposure time to the activity.
In mining environments, this represents not only compliance, but real mitigation of operational risk.
Standardization and scalability
The case was not limited to a single team.
The solution was implemented across all supervisory areas within the management team and replicated to other units, in addition to being included in formal training and integrated into Vale’s official technical procedures.
This demonstrates the solution’s scalability and industrial applicability.
Why is the Screw Jack® strategic for mining companies?
Because it simultaneously addresses three critical pillars of industrial maintenance:
- Operational safety
- MTTR reduction
- Reduction in labor costs
- Increased asset availability
It is a solution that directly impacts the operation’s strategic indicators.