GembaPro: Bridging the Heavy Equipment Training Gap with Innovative Solutions

Written by Artemiy Vereshchinskiy and Ando Konstantinidi at GembaPro

The mining sector is grappling with a significant and costly challenge: the hidden costs of operator skill gaps. Unplanned equipment downtime is by far the biggest driver of these costs, with conservative estimates putting the figure at around $187,500 an hour. The root cause of these costs often lies in undertrained and inexperienced operators who lack the knowledge needed to properly operate and maintain equipment backfiring in a number of ways.

Firstly, as many do not know how to properly operate equipment, misuse and excessive wear happens. Secondly, improper maintenance is another major factor; without adequate training, operators fail to perform the necessary care, which leads to increased frequency of maintenance, ultimately driving cost of ownership up. Lastly, inadequate operator skills can sometimes lead to safety incidents, which not only pose health risks but can also paralyze operations during investigations and clearances.

These factors result in excessive costs for mining companies, including higher maintenance expenses and lost revenues from equipment downtime. Downtime not only affects the productivity of a single machine but can also impact entire operations, especially when serious accidents occur. In an industry where margins are tight, these hidden costs can have a significant impact on profitability.

The reason for these skill gaps lies in the changing dynamics of the mining industry. Over the past 30 years, lifelong employment has become increasingly rare. The experienced professionals who learned through decades of trial and error are now retiring, and they are taking with them invaluable knowledge that is difficult to replace. The new workforce, on the other hand, often lacks the time or opportunity to become fully competent, partly due to high turnover rates and the demand for immediate productivity.

In addition, with production numbers on the rise and an increasingly transient workforce, traditional in-person training models are no longer sufficient to meet the industry’s needs. The most common alternatives—eLearning and simulators—have significant downsides. Classic eLearning relies on lengthy presentations and reading materials that are often disengaging and fail to effectively impart crucial knowledge to operators. Simulators, while providing hands-on practice, are expensive and inaccessible for many operations. They also often lack a focus on theoretical learning and maintenance, which are crucial components for well-rounded operator training.

Recognizing these challenges, McKinsey & BCG alumni Ando Konstantinidi and Roman Khrulev set out to create a solution that would combine the best of both worlds: the accessibility of eLearning and the practical value of simulators. Together with ex-Yandex tech expert Artemii Vereshchinskii, they founded GembaPro—a training platform designed to bridge the skills gap in the mining industry.

GembaPro specializes in training solutions for heavy equipment operators, focusing on simulation-driven, interactive lessons that deliver real-world insights on operational best practices and maintenance procedures. Unlike traditional simulators, GembaPro’s solution does not require any hardware and can be run on any computer or tablet, making it an accessible option even for remote mining sites. Training materials are customized down to specific makes and models of mining equipment, helping operators become adept with the exact machines they are working with. By providing a highly realistic and immersive experience, GembaPro aims to ensure that training is not only comprehensive but also applicable to real-world scenarios.

Safety is a key focus for GembaPro. Proper training reduces the likelihood of accidents, which is crucial in the mining industry. Well-trained operators make fewer mistakes, helping maintain safety records and avoid costly disruptions. By equipping operators with essential safety knowledge, GembaPro fosters a culture of safety in mining.

Effective training also boosts productivity. Well-trained operators work efficiently and make better decisions, contributing to overall productivity. GembaPro’s training modules improve efficiency and instill confidence, enabling operators to perform their tasks competently.

GembaPro’s approach is already making a difference. In collaboration with Dry Fork Coal, GembaPro recently rolled out a training program focused on haul truck operators. Despite many of the crew members having more than five years of hands-on experience, the results were striking. The crew showed a 15 per cent improvement in knowledge and truck handling skills following the training. The training elevated their understanding of the equipment and translated into measurable outcomes: Dry Fork Coal reported significant cost savings in maintenance during the first quarter after the program was implemented.

According to Nick Ullrich, the training coordinator at Dry Fork Coal, “GembaPro is great – they have managed to exceed my expectations and deliver a detailed and easy to use training system that even operators with years of experience managed to learn something new from. Soon after taking the training, we saw improvement in pre-start inspection quality, better reports, and early catches of equipment damage, which already saved us more than six figures. Definitely something to look for.”

This example highlights how GembaPro’s solution goes beyond basic training. By focusing on specific machine models, practical maintenance practices, and real-world scenarios, GembaPro ensures that operators are not only technically proficient but also capable of anticipating and preventing problems. The result is a more proactive approach to equipment handling, leading to fewer breakdowns, lower maintenance costs, and ultimately, greater operational efficiency.

GembaPro is not just providing training—it is offering a strategic response to a critical industry challenge. As experienced operators retire, the need for robust, scalable, and effective training solutions becomes increasingly urgent. GembaPro’s approach ensures that the next generation of mining professionals is well-prepared, equipped with both theoretical knowledge and practical skills, and ready to meet the demands of the industry. By combining accessibility, practical simulations, and a focus on real-world equipment issues, GembaPro is helping secure the future of mining by bridging the skills gap and empowering operators to perform at their best.

“We started GembaPro to make professional education accessible and engaging for frontline workers in mining and construction,” says Ando Konstantinidi, CEO of GembaPro. “The key to effective learning is creating an experience that is easy to understand and captures attention. This ultimately helps build the skilled operators of tomorrow—something the industry truly needs.”

Learn more about GembaPro in this video:

About Artemiy Vereshchinskiy (left) and Ando Konstantinidi (right)
Ando Konstantinidi is the CEO of GembaPro and has expertise in helping industrial companies with frontline worker training and capability assessment. During his time at McKinsey, he worked with large mining enterprises on capability assessment programs and optimization of capital expenditures.
https://www.linkedin.com/in/andokonstantinidi/
Artemiy Vereshchinskiy is the CTO of GembaPro with a passion for online education. He previously worked at Yandex Praktikum, a leading EdTech company in CIS, and has experience rebuilding company-wide design systems.
https://www.linkedin.com/in/onepx/

GembaPro is an interactive training software helping mining & construction companies upskill equipment operators, increase productivity and reduce safety risks.  
https://gembapro.com
https://www.linkedin.com/company/gembapro/

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