How OceanaGold Uses Cat^® Reman to Save Time and Money

Keep Working: From One Lifecycle to the Next

Cat Reman parts are used all over the world, wherever customers need convenient lasting solutions offered at an affordable cost. Among these far-flung locations is the South Island of New Zealand, where the work that customers accomplish seems as impressive as the snow-capped mountains and sweeping valleys found throughout the “Land of the Long White Cloud.”

There on the South Island, OceanaGold has been running the Macraes Operation since 1990, with a large-scale surface mine, an underground mine and an adjacent process plant. Between these sites, 300 employees work to support the company’s annual gold production, split between approximately 75% open pit production and 25% underground production operations.

A mine of this scale needs dependable support to prioritize uptime and productivity. So, for the duration of their time at Macraes, OceanaGold has relied on support from their dealer, Terra Cat. Speaking to this relationship, Macraes open pit manager Pieter Doelman says, “They've been a key business partner for this operation, and we see them having a critical role for the remainder of the mine life here.”

A key example of the way Terra Cat fills that “critical role” involves three Cat 789C Mining Trucks at Macraes, originally purchased in 2002. With Cat Reman products and the support of their Cat dealer, the OceanaGold team was able to bring new life to this equipment.

Considering Their Options

Each 789C accumulated about 65,000 to 70,000 frame hours before coming to a halt. Once parked, they were left on the sidelines, exposed to the elements. Doelman says, “Over that time, most of the parts and components had been taken off those trucks to keep the rest of the fleet going.” But it wasn’t lost on the OceanaGold team that there was still potential in these durable machines.

Doelman recalls, “We thought, ‘we've got these 789Cs with the 1900 horsepower engine, which are essentially structurally OK. But for the want of a bit more power, can we modify them?’”

Terra Cat’s David Baillie, a mining account manager who works on site at Macraes, explains how Cat parts are designed for situations like this. “One of the key advantages of any Caterpillar product in the mining range is its rebuild-ability. They can get the productivity out of that machine and get it back to like new performance again. And we can do that multiple times, with different levels of rebuild [options] to suit their needs.”

Once OceanaGold realized the potential this service offered to their equipment, the engines were taken to Terra Cat’s Component Rebuild Centre (CRC) in Christchurch, where they were stripped down to the bare frame for a full evaluation. Darren Fleck, CRC manager at Terra Cat, shares how the CRC and its 15 team members can support this work: “The Component Rebuild Centre is a purpose-built facility, primarily designed for rebuilding powertrain and hydraulic components. The building is pressurized, air conditioned and set out with a workflow that suits the whole contamination control process.”

Considering this information and the fact that the truck frames were in good overall condition, OceanaGold decided to rebuild them — upgrading each truck to a 789D high-horsepower powertrain. From beginning to end, the rebuild process took about 12 months for all three machines — for a fraction of the cost and less downtime than purchasing new.

“Caterpillar is a one-stop shop. From transmissions and chassis to engine, it’s all Caterpillar. It all relates to each other and it’s one system,” says Greg McKay, workshop supervisor at OceanaGold.

The Cat Reman Difference

The three Cat 789C rebuilds are a prime example of how Cat equipment is designed for multiple lives, all while providing a cost-effective solution. Each machine was returned to service for a fraction of the cost of a new one, backed by a 12-month, same-as-new Caterpillar Limited Warranty¹.

When considering the results that Cat Reman has brought to their operation, Glover says, “The biggest proof for us is the hours that are on the machinery. We've got trucks running in the high 80,000-hour mark and they're still turning like they were from their dock. That in itself is proof that Cat Reman works.”

Beyond the 789C Cat rebuild, OceanaGold uses Cat Reman parts from suspension cylinders to engines and drivetrains — and OceanaGold saves on each product when they return the original end-of-life part (also known as “core”) to their dealer. After they return acceptable core to Terra Cat, they receive a core refund that reduces the price on Cat Reman replacement parts. That core, once accepted by Terra Cat, is then sent to a Cat Reman facility where it’s disassembled down to its piece parts, salvaged, remanufactured and tested before re-entering the supply chain as a new Cat Reman product, a drop-in solution that offers like new quality.

In addition to cost, “the chief advantage of using the Cat Reman parts and components in those rebuilds was about time,” says Doelman. “We were able to get these trucks rebuilt in a very short time frame compared with ordering a new truck.”

Tina Shand, an operator who drives the rebuilt trucks, adds her own perspective: “Compared to a lot of the old ones on site, they are definitely a lot faster. The cab is very clean, everything about it appears to be like new. And they're definitely the best trucks on site to drive.”

Daniel Thomas, another operator, agrees: “You can definitely tell the difference in the horsepower and the times that it takes to travel uphill between the older series and the newer rebuilds.”

To Baillie, the results speak for themselves: “Many of the equipment here is over 20 years old now and performing really well. For it to feel like a new truck again, from the operator’s perspective — we’re really pleased with how that came out.”

Looking to Rebuild One of Your Assets?

When considering your options, OceanaGold is a testament to how Cat Reman can help you get the job done. Talk to your Cat dealer about Cat Reman options, rebuild strategies and other available services. And visit the Cat Reman hub for more insight on the remanufacturing process, sustainability benefits and more.

Hear from OceanaGold on how Cat Reman made a difference for them