The verdict in three sentences
A mining contractor headquartered in Toronto and running 40 to 200 machines on remote sites in Canada or West Africa invests 33,000 to 100,000 USD (20 to 60 million FCFA) in custom maintenance software, live in 4 to 6 months. The realistic target is +8 points of mechanical availability, moving from breakdown maintenance to plans triggered by hour meters. Without a true offline mode the project fails, because remote pits often rely on intermittent satellite links.
The modules that cut unplanned breakdowns
A 70-tonne excavator standing idle costs the contractor contract penalties and lost billable hours. Most major failures show warning signs that nobody records.
| Module | Key function | Indicative 2026 cost (USD) |
|---|---|---|
| Fleet register and meters | Record per unit, engine hour readings, fuel consumption | 5,000 to 12,000 |
| Preventive maintenance plans | Triggers at 250, 500, 1,000, 2,000 hours per OEM | 7,000 to 17,000 |
| Work orders and breakdowns | Reported by shift supervisor, diagnosis, mechanic time | 7,000 to 17,000 |
| Parts inventory | Stores per site, thresholds, critical parts, transfers | 7,000 to 20,000 |
| Offline mobile app | Workshop and field entry, deferred sync | 5,000 to 20,000 |
| Dashboards | Availability, MTBF, MTTR, cost per engine hour | 3,000 to 15,000 |
A first lot (fleet, preventive plans, work orders, mobile) sits between 33,000 and 50,000 USD. Projects at 85,000 to 100,000 USD add several sites, multi-store inventory and machine telematics feeds.
Off-the-shelf CMMS or custom
| Criterion | Off-the-shelf CMMS | Custom CMMS by Kolonell |
|---|---|---|
| Entry cost | 8,000 to 25,000 USD configuration | 33,000 to 100,000 USD |
| Recurring cost | 40 to 120 USD per user per month | Maintenance 10 to 15 % per year |
| 60 users, 5 years (70 USD) | about 252,000 USD | about 50,000 to 175,000 USD |
| Real offline mode | Often partial | Designed for satellite links |
| Mechanic usability | Dense screens | Simple screens, bilingual |
| Billing to the mine owner | Missing | Available hours and penalties tracked |
| Go-live time | 2 to 4 months | 4 to 6 months |
Math: 60 users x 70 USD x 12 months x 5 years = 252,000 USD.
Indicators before and after
| Indicator | Common situation without CMMS | 12-month target |
|---|---|---|
| Mechanical availability | 72 to 78 % | 80 to 86 % |
| Share of preventive maintenance | 20 to 30 % | 60 % and above |
| Mean time to repair (MTTR) | 18 to 30 hours | 10 to 16 hours |
| Stock-outs on critical parts | 6 to 10 per month | 1 to 2 per month |
| Maintenance cost per engine hour | Not measured | Tracked per unit and model |
Mini case study
Daniel, technical director of a Toronto-based mining contractor, runs 85 machines on two gold sites. Each unit is billed to the mine owner about 75 USD per available hour, on 500 scheduled hours a month. Average availability is 76 %. A 63,000 USD custom CMMS targets +8 points, to 84 %. Monthly gain: 85 machines x 500 hours x 8 % x 75 USD = 255,000 USD of potential additional revenue. Even keeping only a tenth of that, 25,500 USD a month, the project pays back in under three months, before counting fewer parts stock-outs.
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FAQ
How much does fleet maintenance software for a mining contractor cost?
From 33,000 to 100,000 USD custom, depending on machines, sites and stores. A first lot starts between 33,000 and 50,000 USD.
Does the software work without internet on site?
Yes, the mobile app records every entry offline and syncs as soon as a satellite or 4G link is available. One daily sync is enough for most sites.
How are preventive services triggered?
By hour meter, following OEM intervals (250, 500, 1,000 hours), or by calendar. The workshop lead gets the list of upcoming jobs 50 hours before they fall due.
What availability gain can we expect?
A +8 point target at 12 months is realistic once preventive work exceeds 60 %. Results also depend on parts availability and data entry discipline.
How long until go-live?
Four to six months, with a one-month pilot on one site and 15 to 20 machines. Rollout to the second site then takes 3 to 4 weeks.
Let's scope your project. Send us your fleet list, sites and connectivity constraints: we will price a first lot at 33,000 to 50,000 USD with a 4 to 6 month plan. Detailed quote within 48 h. WhatsApp +221 77 596 93 33.
Mohamed Bah
Fondateur, Kolonell
Passionate about digital and entrepreneurship in Africa, Mohamed has been helping Sénégalese businesses with their digital transformation since 2020. Founder of Kolonell, he believes every SME deserves a professional and accessible online présence.
