Client Experiences - Ramesys Maintenance Budgeting Reporting and Analytics System (MBRS)

The Client

A large, long-established open-pit gold mining operation, in production for decades and currently operating with a multi-year Life of Mine (LoM). The site runs a complex mobile and fixed plant maintenance program that plays a critical role in cost control and asset availability.

The Challenge

The client had outgrown their enormous, labour-intensive,error-prone Excel budgeting process. Activity-based planning was unreliable, reporting was late and inaccurate, life-cycle costing was non-existent and confidence in the maintenance department was low.

The Solution

The site implemented the Ramesys Maintenance Budgeting Reporting and Analytics System (MBRS), integrated to its ERP CMMS for asset scheduling.

Excel-based models were replaced with a structured, system-driven approach that automatically generated maintenance budgets from validated asset, BoM, task, and scheduling data.

MBRS was linked directly to the mine plan, enabling consistent LoM planning, equipment life-cycle costing, and faster, more transparent budget updates.

The Outcomes

The shift to Ramesys MBRS delivered immediate and tangible wins.

The maintenance team

1. 1. Uncovered and corrected long-standing issues in master data
   2. Identified missing maintenance tasks and incorrect task intervals 
   3. Validated rotable pricing
   4. Eliminated overstated breakdown costs
   5. And was able to rework its warehouse process to ensure effective JIT inventory levels

The Planners have a reliable, driver-based budgeting framework that allows them to turnaround forecast and budget models in under 24hours.

In addition to achieving substantial monthly time and cost savings, the client was able to evaluate multiple scenarios across its aging haul truck fleet, comparing replacement and rebuild options. As an outcome, they were able to reduce capital spend by $40 million over five years.

About Ramesys Global

Our Maintenance Budgeting Reporting and Analytics System (MBRS) is purpose-built to help mining companies optimise their plant and equipment maintenance by creating zero-based budgets and forecasts at equipment, task, work order and BOM levels.

For over two decades we have helped mining companies to achieve a transparent understanding of their cost performance, develop a cost-conscious culture and create a single source of truth that helps managers make better decisions, faster.