We Solved the Idling Problem

– In the first week of using the TMS Platform, we recorded 30 idle-related alerts daily—on just one machine. With eight machines in operation, that added up to over 200 alerts each day. A quick calculation revealed that this was costing us hundreds of thousands annually,” says Paweł Chrapek, Production Director at the Melafir Quarry in Tłumaczów, Regnars Sp. z o. o.

How did your relationship with TMS begin?

When I joined the melaphyre quarry in Tłumaczów seven years ago, I quickly realized we lacked an effective system to manage our fleet of machines and processing plants. Our equipment came from various manufacturers, and we had three separate processing plants to oversee. Additionally, our location near the Czech border presented GSM connectivity issues in some pits. We needed a company that could integrate all these components into a single system while addressing our unique challenges.

Which devices have you connected to the TMS Platform?

We’ve installed over 25 measuring points across various equipment, including mobile machines like excavators, loaders, and telescopic lifts. The system also covers all processing plants, monitoring belt weighers from the input and some product conveyor belts as well.

What results have you achieved?

The biggest benefit has been gaining real-time awareness of machine and equipment operations. Now, we can monitor production values for individual shifts, products, and equipment performance. This data has helped us significantly improve productivity, particularly during night shifts. 

What about specific, measurable savings?

Idling gears were a major issue for us. In the first week of using the TMS Platform, we detected 30 idle-related alerts per day on a single machine—over 200 daily across all eight machines. This data showed we were losing hundreds of thousands annually. Armed with this information, we addressed the issue with our crew, using maps and charts generated by TMS to visualize the problem.

We’ve also gained better control over our entire fuel cycle—from delivery to machine refueling to final consumption. Every machine and operator is now monitored, giving us the transparency and control we were missing.

Reducing idle time and optimizing fuel consumption were the most impactful changes, allowing the system to pay for itself in just 14 months.

How has TMS improved processing plant management?

The TMS Platform has made managing our plants far more convenient. Previously, we relied on operators to manually report production volumes, which caused delays. Now, plant metering provides real-time data on productivity for specific products and shifts. If an issue arises, we can immediately identify and address it, rather than waiting hours, days, or weeks to react.

What impact has TMS had on managerial work?

Every day, I receive tailored reports with critical KPIs and a daily Machine Picture overview. This allows me to manage the quarry and communicate with staff using clear, objective data.

The platform goes beyond raw numbers, presenting the data visually with graphs that are easy to interpret. It’s an invaluable tool for managing a complex site like an open-pit mine

Why did you choose TMS?

The TMS Platform’s ability to integrate machines from different manufacturers was a game-changer. At our quarry, we use equipment from Volvo, CAT, Komatsu, and Merlo. Instead of managing separate monitoring systems for each, TMS consolidates everything into one unified platform.

It also integrates stationary equipment like crushers and screens, which was highly innovative when we began.

Another key factor was the automatic generation of customized reports. Every day, I receive a performance summary, complete with graphs that show machine operations in detail. I no longer have to chase data or guess what’s happening at the mine—it’s all at my fingertips.

How do these reports assist in daily operations?

The reports provide near-instant insight into machine performance and production volumes. Every morning, the production and mining teams review the previous day’s results. If we spot any discrepancies, we discuss them immediately to identify causes, whether it’s downtime or operational inefficiencies.

The TMS Platform also maintains a full operating history, enabling us to analyze data over long periods. This capability helps us verify trends and make informed decisions.

What memorable situation involved the TMS Platform?

One Saturday, during the second shift, I was informed of an accident at the quarry. A loaded dumper had overturned while descending a hill. Thankfully, the operators were unharmed and claimed the brakes had failed. While the service team inspected the machine, I used the TMS Platform to analyze the incident step by step. It revealed that the operators had been speeding, causing the dumper to lose control. The brakes were fully functional. Without TMS, we would have assumed a machine failure rather than operator error. This incident served as a critical lesson for the entire team about accountability and safety.

What is it like working with the TMS team?

The TMS team is fantastic—responsive, professional, and solution-focused. If they encounter a challenge, they always analyze it thoroughly and often come back with a solution.

In one sentence: TMS is…

Data-driven excellence in operational management.

Interviewed by Sabina Szewczyk-Wajda