Replacing the brake pads on a haul truck when they reach their 1,000-mile use will limit costs to about $155 -- whereas waiting longer can damage the rotor, adding $230 to the original cost, experts say. Those outcomes reflect the difference between reactive maintenance, which waits for breakdowns to occur, and proactive maintenance (PM), which seeks to eliminate breakdowns. Using PM "will significantly reduce the owning and operating costs of a machine if done properly," writes equipment expert Stan Orr, who recommends customizing PM for each machine, reviewing hour intervals for the machines and choosing a point person to implement PM.

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