Beyond Spare Parts: Why "Tick and Flick" is More Expensive Than Spare Parts

Is your maintenance team stuck in a "replace and restock" cycle that never actually stops the breakdowns?

In this episode of Maintenance Break, Pete and Drew tear down a real-world case study: a Hitachi EH3500 haul truck with an HV cabinet door that failed mid-shift. While the site blamed a lack of spares, the root cause was a "tick and flick" culture that ignored a visible defect for weeks.

Using the JEBS PCR Triad, they examine how a failure in the "Check" phase of the PDCA cycle creates a ripple effect:

PERFORMANCE: Why 4.5 hours of immediate downtime was entirely preventable.
COST: The "financial leakage" of unplanned cannibalization—and why raiding a donor truck doubles your labor costs.

RISK: The safety hazard of falling heavy components and the danger of inspections that lack integrity.

In this episode:

The Cannibalization Trap: Why raiding healthy trucks is a maintenance sin.
Defects vs. Parts: Why reliability is found in tool-time inspections, not a warehouse.
The "Check the Check" Strategy: A leadership tactic to close the loop between the PM sheet and the planning office.

Stop the "slow-motion car crashes" on your site and turn ticked boxes into operational control.

Listen now and keep those assets running!

Disclaimer: Maintenance Break utilises AI voice clones of our hosts. All insights, technical data, and industry strategies are developed by human experts based on real-world reliability experience.

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Episoder(24)

Operational Readiness: Why the Work Before the Work Determines Everything

Most sites focus on maintaining assets once they're running. Operational Readiness is everything that has to happen before the first shift starts — and when it's skipped, the performance gap costs mor...

22 Jun 10min

Asset Management Plans: The Ultimate Operational Handshake

In this episode, Pete and Drew demystify the Asset Management Plan (AMP), to reveal why it is the ultimate alignment tool between operations and maintenance. They break down how combining your Operati...

8 Jun 8min

When the Plan Unravels: Swinging Loads & Missing Procedures

The JHA was done. The OEM procedure was on the table. The crew were trying to do the right thing. And a worker still ended up on the ground with a serious leg laceration. In this episode, Pete and Dre...

25 Mai 8min

Still Running… But is it reliable?

Is your plant running because it's reliable — or because your team is holding it together with workarounds and tribal knowledge? In this episode, Pete and Drew tackle one of the most common misconcept...

11 Mai 9min

No Visibility, No Control: Fixing the Off-Site Repair Process

You send a gearbox out the gate and it vanishes. No status update, no confirmed lead time, and an invoice that lands like a lead balloon much larger than you expect. Sound familiar? In this episode, P...

27 Apr 7min

When Jumpstarts Become Normal: Chronic Failures & the Cost of Looking Away

Nobody questions the jump-start ute — until someone does. In this episode, Pete and Drew break down a chronic breakdown event where a dedicated vehicle and fitter were burning up to eight hours a shif...

13 Apr 6min

Single Point of Failure: Guardrails, Modifications & the EX5600 Incident

Four metres. That's not a stumble — that's a life-changer. In this episode, Pete and Drew break down Safety Alert SA26-02 out of the Hunter Valley, where a worker fell from a Hitachi EX5600 excavator ...

30 Mar 7min

The 15-Year Crane Problem: When Chemistry Beat Mechanics

For fifteen years, a primary production rail crane was the site’s biggest headache. Availability sat at just 65%, improvement projects kept failing, and the team had started accepting the problem as “...

16 Mar 8min