From the ground up: A quarry manager's unexpected path to success
It wasn’t part of the grand plan, but a chance decision that turned into a career”. - Sean McIntyre, Quarry Manager
Sometimes, things don’t go to plan, and that can be a good thing. Other times, planning and preparation is the key to success.
Sean McIntyre, Quarry Manager for Fulton Hogan has definitely experienced both sides of the coin. From the deep drilling sites of Western Australia, to the graywacke peaks of the East Coast, McIntyre talks about how he became a Quarry Manager, and what makes him successful.
Before ending up at Matawai, McIntyre tells us he “was over in Australia, drilling for Western Deep Hole Drilling.” This was exploration drilling in Western Australia, around Perth and south of Kalgoorlie.
On returning to New Zealand, he took up studies in engineering, not knowing that things were about to change - we think, for the better. It was while he was studying, that “somehow, don’t ask me how, got asked to come into quarries. And he said, yep, I’ll give it a go.” And just like that, plans changed.
Funnily enough, when compared to the intensive nature of his current role, his entry into quarry work was casual, almost dismissive. Just something to do part time while he finished his studies, he recalls, but he found he “actually enjoyed it, and ended up doing it, hence to this day.”[sic].
One moment he was focused on engineering and then – almost by accident – he’s running a critical piece of NZ infrastructure, helping to build, rebuild and connect communities. It wasn’t part of the grand plan, but a chance decision that turned into a career.
We have had this (R5) now for 250 hrs... and we have doubled production. - Sean McIntyre, Quarry Manager
Early Days
Working on various machines, loaders, dozers, and mobile jaw and cone, Sean learned different aspects of quarry operations, from the ground up, so to speak. But the old equipment struggled.
"We used to have a jaw and a cone, which were really old at the time and we struggled to make M4 because of the weathering" he'd explain. But about eight years ago, everything changed.
"We decided to change to an impactor and we got an R3 … I think it was the first one in New Zealand." It was a bold move that took good planning and it paid off. "With the impactor, we managed to get M4 pretty much straight away." It was the first big improvement of many that Sean implemented at the Fulton Hogan quarry, which had a flywheel effect.
The Matawai quarry became more than just a workplace, Sean was turning it into an efficient production site, building relationships and supporting the local community and industry.
Sean gives us the low down in the video (left) "This quarry is a greywacke quarry," he'd explains, "We produce aggregate mainly for forestry, but we do produce material for the highways and local council.” In industry spec terms, thats M4, AP65 and GAP products.
While we’re chatting with Sean and the team, you get a sense of camaraderie - Sean is one of those Managers that puts his team first. He talks about making sure there’s enough people on the ground to do the job, that they are clear on what the days work is, what they are producing, and above all, that they are safe on the job.
Coming Full Circle
When Cyclone Gabrielle tore through the East Coast, leaving a wake of destruction, Sean saw more than just a disaster - he saw an opportunity to help his community rebuild.
“After Gabriel, we had a fair bit of damage around Gisborne, East Coast area,” he recalls with a typical Kiwi understatement. The resources to rebuild and upgrade the roading was going to be massive, and the question was - could Sean and his team keep up?
The guys are impressed with how the R5 goes, the ease of operation, and changing blow bars and skirting. - Sean McIntyre, Quarry Manager
Having since moved on from the R3 to an alternative supplier, this quarry was struggling for real support, and their current machinery arrangement wasn’t going to cut it. So it became clear that another step change was required.
This time, Sean left nothing to chance and made sure his move was well-planned, speaking to Quarry Owners up and down the country before deciding to go back to his original relationship with Keestrack from Equip2 - this time purchasing an R5.
It’s a decision he clearly hasn’t regretted. “When we first got the first R3, production was good, but this is way better.” Features like hydraulic rams at the back to level the machine out, the split deck and the swing return arm were small innovations that made a big difference on site.
Thanks to the R5, Sean and his team were able to keep up with production for the Gabrielle rebuild - in fact, they had to purchase a stacker to deal with the extra production.
Secrets to Success
Like most successful Quarry Managers, Sean pays attention to more than just the upfront purchase. Safety, production time versus down time and repairs are a huge consideration and this is where Keestrack, Equip2 and the R5 in particular really add value to his quarry.
“One of the main reasons with these guys is production… And every time you’re broken down and you’re not crushing, you’re losing money. So it’s not actually the repair bill, it’s how quick you can get the parts… These guys have been great in supplying us with parts and giving us any help when we needed it.”
Advanced safety features on R5 also impressed Sean, as he mentions “You can just lower the screen down right to the ground, and the guys feel safe working on it.”
Because of high production we even had to get a stacker to help out. - Sean McIntyre, Quarry Manager
Pictured cleaning his glasses is Seans right hand man, who comments how much safer the R5 is compared to the last machine they ran at the quarry. For him it was the biggest thing, the safety aspect. And he is loving his new R5 Impactor.
Sean, is somehow both gruff and jovial, giving his men a hard time (in a good way), has the nack of running a quarry like a well oiled machine. Time is not wasted but rather efficiency is a key driver, and he mentions the “immense” savings and efficiency of the R5. At a calculated estimate, Sean states the time saved is excess of a week.
Even when repairs are needed, getting parts and service technicians to the remote site doesn’t seem to have posed a problem for Sean, who goes on to say “I’ve been impressed with Equip2.
They’ve stood by their word, they delivered when they said they were going to deliver, they’ve supplied parts when they said they’d have parts, and they’ve turned up when they’ve said they’ve turned up, every time, on time.” You could tell he appreciates it.
His advice to other professionals was simple and profound: “If you’re looking at buying a Crusher - impact Crusher - I really recommend going to someone that’s got one operating, asking them if you can watch it and get their feedback… The way this one’s been going so far, I’d definitely look at buying another one.”
As we wrap up the interview, we can’t help but notice the men and machines working steadily on, against the backdrop of the blue East Coast sky and the ever changing quarry face.
But Sean sees much more - as he puts it, “ it’s making sure operations are running smoothly. Just get orders coming in, making sure we have the product available and can supply our clients.” and with this plant & support from Equip2, he can focus on that.
Listen to the full interview below for industry insights, Seans’ seasoned advice and how you can help you move your quarry forward.
Because of the 2-deck, we can scalp out and crush at the same time, so we have saved us getting another plant. - Sean McIntyre, Quarry Manager
