Maximizing Profits Through Effective Record-Keeping in Crushing and Screening Operations

What’s the biggest, cost-effective change you can make to increase profits in your crushing and screening operation? The answer might surprise you: an efficient record-keeping system. While it may seem unremarkable, a well-organized record-keeping system that tracks production is the foundation of your efforts to boost productivity. Here’s why it matters:

1. Measuring Progress for Meaningful Improvement

Without accurate records, it’s impossible to know if your efforts are making a difference. Record-keeping provides the necessary data to assess whether changes in operations lead to improved results. If you’re not tracking performance, you’re just guessing.

2. Improved Performance Through Measurement

Studies show that simply measuring performance can drive improvement. People naturally want to look good; tracking their successes and progress motivates your crew to do their best. Recognizing record production days or rewarding improvements in reducing downtime creates a sense of ownership and pride in their work. When your team feels invested, they’re more likely to provide the data you need.

3. Identifying Downtime and Driving Improvement

An effective record-keeping system records downtime events, daily production, weather, and other variables. Knowing how many minutes per day your operation is down (whether for scheduled maintenance or unexpected issues) is essential. Building a database of downtime causes allows you to take targeted action to reduce delays. As you track these improvements, you’ll see which solutions are working.

4. Unexpected Benefits of Record-Keeping

A comprehensive record-keeping system unlocks insights that can lead to even greater productivity. Here’s what it enables you to do:

• Test products effectively and understand which ones deliver results.
• Analyze the impact of weather on productivity.
• Assess how different pit or blast conditions affect performance.
• Implement performance management systems for your team.
• Enhance your preventative maintenance program.
• Improve job bidding accuracy by using historical data to predict production outcomes.

Getting Started: Establishing a Basic Record-Keeping System

Getting started doesn’t have to be complicated. Identify someone in your team—often the tower operator—as the designated record-keeper. This can be done using a simple binder for paper records, a computer, or even a smartphone or tablet in the tower.

A basic system should track:

• Total hours worked
• Daily production tonnage
• Scheduled downtime with reasons (integrated with maintenance records)
• Unscheduled downtime with reasons
• Weather conditions
• Pit conditions

From this data, you can calculate:

• Production tonnage per hour
• Uptime percentage (Availability = Payable Hours)

Over time, these metrics reveal the impact of operational changes, enabling you to make data-driven decisions.

Advanced Record-Keeping for Deeper Insights

Once you’re comfortable with basic record-keeping, consider expanding to include:

• Daily production costs
• Profit and loss per shift

While record-keeping might seem mundane, it’s an invaluable tool. Many operations have some form of record-keeping in place, but most could benefit from an upgrade. Take a step back and assess your system—there’s always room for improvement.