Metso Insights Blog Mining and metals blog Solving mining’s labor crisis with smart solutions
Mining
Jan 17, 2025

Digging deeper: Solving mining’s labor crisis with smart solutions

Mikko Koivunen
Mikko Koivunen
Director, Digital Commercialization
Nichole Pritchard
Nichole Pritchard
Senior Manager, Technical Training
The global mining industry is currently grappling with significant labor shortages, adding to the ongoing challenges of increasing production and managing operations in the face of rapidly fluctuating mineral prices.

First published on mining.com in October 2024

The remote nature of many sites poses a first hurdle, with personnel finding the long commute or fly in and fly out approach to be challenging over time. Recent studies highlight that mining is not always a top career choice for young professionals, further complicating efforts to attract new talent. Additionally, a wave of retirements is right around the corner for the industry, threatening to widen the labor gap and intensify staffing issues.

Without addressing these workforce challenges, the industry’s ability to meet production demands and capitalize on market opportunities could be severely hindered. The shortage of skilled staff not only impacts operational efficiency but also poses a risk to the industry’s long-term sustainability.

As the sector navigates these hurdles, innovative solutions and strategic workforce planning will be crucial to securing its future. Methods of working smarter and not necessarily harder need to be examined to pinpoint the most cost-effective opportunities to “solve” or at least improve the current labor situation before it becomes a full-blown crisis.

Practice makes perfect – the power of training

One of the first places to start looking for hidden opportunities is by examining current and planned training programs that have been put in place. Modern mining  involves a vast range of specialized roles and skills, including minerals processing knowledge, maintenance know-how, equipment operation skills, an understanding of inventory management as well as familiarity with automation and digital tools.

Further complicating things is that many sites have diverse types of equipment as well as differing models and machine brands in their flowsheets. For example, site teams may need to know how to operate and maintain crushing and screening equipment, grinding mills, filtration systems all the way through to filters and other dewatering processes.

Adding another layer of complexity is that all these machines need to work in an integrated manner, as problems in one process stage often impact other equipment downstream of where the first issue develops. It is easy to see how a gap can develop as normal turnover can lead to skilled personnel leaving and replacement team members missing out critical information or knowledge gained from years of experience.

Operator training simulators can recreate a processing circuit, allowing operators to train in a virtual and safe environment.
Operator training simulators can recreate a processing circuit, allowing operators to train in a virtual and safe environment.

Training programs can be game changers in bridging the gap. Whether it is live or remote training, programs can be developed to arm operators or service teams with the knowledge that can allow them to perform more efficiently, speeding up the safe completion of maintenance work.

A new tool that is making an impact at many sites is the use of Operator Training Simulators, such as Metso Academy, that virtually recreate generic equipment or customized plant specific circuits to allow operators to gain experience operating equipment in a safe and controlled environment.

In the case of plant specific OTS systems, the operator in training can experiment with how his or her process reacts when operating parameters are changed in the virtual environment and can gain a greater understanding of how all the equipment in their flowsheet can work together to generate the highest performance. Well trained and higher performing staff can work more quickly and effectively, easing the load on existing staffing resources.

Going remote – monitoring solutions that free up site staff

With multiple types of minerals processing equipment on site, and the recurring need to maximize production, service interruptions and shutdowns caused by high wear and tear can be a common occurrence. Service staff need to constantly monitor parts and equipment, often for a quick visual inspection, but in some cases for a deeper audit to see how a given machine or component is performing or if it needs servicing.

Remote monitoring supported by expert teams, such as with the Metso Performance Centers can play a key role in reducing the load on a site’s maintenance personnel. Equipment operating data is fed into remote monitoring data centers, where experts can examine the incoming information looking for trends, anomalies as well as provide expert advice.

Taking analyzers as an example, remote monitoring can help see potential problems coming as well as identify when recalibration is needed. Taking it a step further, the recalibration itself can even be done remotely – further reducing the need for an on-site specialist or technician and removing the need to have someone fly in simply for the recalibration step.

Remote monitoring coupled with expertise can significantly reduce the time needed for physical inspections and free up staff to tackle other maintenance tasks.

Remote monitoring with expertise can drastically reduce the time needed for physical inspections, identifying issues before they balloon into major problems.
Remote monitoring with expertise can drastically reduce the time needed for physical inspections, identifying issues before they balloon into major problems.

Parts that last – reducing the maintenance load from service stops

Another opportunity, sometimes seemingly hiding in plain sight, is the choice of wear parts used in various equipment at each process stage. Many sites can easily fall into the habit of simply reordering the liners they have been using since the equipment such as a new crusher was first installed. However, ore characteristics and operating parameters may have changed over time, leading to the current liners no longer having the same performance as initially achieved.

Crusher wear parts, for example, are put to the test in tough environments that lead to high wear and tear. Longer lasting crusher liners can have a significant impact on the number of shutdowns required and the labor needed from maintenance teams. Fewer change-outs can free up your personnel for other tasks and increase safety.

Hard-wearing options such as MX for cones, specially designed for large cone crushers, can reduce downtime by as much as half. What’s more, highly wear resistant protective wear parts, such as Poly-Cer, can provide an opportunity to align maintenance cycles with working wears. This can bring additional advantages such as reduced downtime, improved use of labor resources and less risk exposure for site staff.

Patented Poly-Cer protective wears are designed to enhance performance and maximize efficiency, for seamless operation and extended wear life.
Patented Poly-Cer protective wears are designed to enhance performance and maximize efficiency, for seamless operation and extended wear life.

Leaving no stone unturned

When dealing with the labor shortage, no one solution will solve all the issues. Taking a holistic  approach and examining how training, remote monitoring solutions as well as equipment and parts that require less maintenance or change outs can all have their place. Bringing in a trusted partner with knowledge that covers a wide range of equipment but also has deep expertise into how the machines and parts interact can bring immediate dividends and become a cornerstone of ensuring your site is able to upskill and retain your most valuable producing assets – your people.

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