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Curso: Gestión de Equipo Pesado

Especialidad: Mantenimiento de Maquinaria Pesada


6to Semestre

Profesor: Darío Frías


TECSUP 2018

Mantenimiento de Maquinaria Pesada 1


UNIDAD 01
FUNDAMENTOS DEL MODELO DE GESTIÓN DEL EQUIPO
PESADO

SESIÓN: 01
Mantenimiento de Maquinaria Pesada 2
CAPACIDADES TERMINALES
• Diseñar sistemas de gestión de la producción y
disponibilidad del Equipo Pesado; planificando,
controlando y administrando los equipos con el
objetivo de lograr su máxima productividad al menor
coste
• Elaborar el planeamiento eficaz del ciclo operacional
de los equipos pesados, proyectando los costos
derivados de la operación.
• Evaluar la factibilidad técnica y económica para la
adquisición y reemplazo del equipo pesado.

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COMPETENCIAS ESPECIFICAS
This presentation provides a general overview
of the 5 elements of Mining Equipment
Management, what is included and what
should be our role through out the entire life
cycle of the equipment.

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CONTENIDOS DE LA SESIÓN
• What is mining equipment management?
• The Partnership Challenge - “Cost per Ton”
• Selection
• Operations and Project Management
• Repair & Maintenance Management
• Business Management
• Replacement, Rebuild, Disposal

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What is mining equipment management?

Mining Equipment Management is the overall management of


site-specific processes and activities involved through the
entire lifecycle of the machine.

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The Partnership Challenge - “Cost per Ton”

Owning Cost Operating Cost

+
Purchase Price Operator
Interest Tires / UC
Insurance Fuel
Depreciation Maintenance
Tax Repairs

Productivity
Payload
Cycle Time
Usage
Availability
Utilization
Continuation…..

Which do we analyze?
Which do we
manage?
Which do we
influence?
How often we analyze?
Continuation…..

• Selection:
What do I need to efficiently get the job done?

• Operations & Project Management:


How can I achieve more productivity and efficiency?

• Repair and Maintenance Management:


How can I develop capabilities that will lower my risk to obtain
optimum life, availability, and utilization?

• Business Management:
How do I get data to manage my business that will enable
proactive fleet management decisions?

• Rebuild/Resale/Disposal:
What is the most cost effective lifecycle plan for my asset[s]?
Selection
• Machine Lifecycle, What machine do I need to
efficiently get the job done?

What do I need to efficiently get the job


done?

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Continuation…..
Mining Project Existing Mining Operation
(Stages in the Life of a Mine) (Stages)

Exploration Extraction
Project Evaluation (Feasibility Study) Drill + Blast + Load + Haul
Development & Construction Processing
Production or Exploitation Smelting
Closure & Reclamation Refinement

Two Scenarios to Consider


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Continuation…..
Understand in what phase the mining
operation / project is.
Consider all factors for acquisition
Balance O&O Costs over Productivity
Get involve in the earliest possible stage of
the mining operation

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Operations and Project Management
• Machine Lifecycle; How can I achieve more
productivity and efficiency?

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Continuation…..

Load & Dump


Drill & Blast
Area
Lower cost
Increase
productivity

Load Haul Road


Management Management

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Continuation…..

Cost / Hour Cost / Ton Tons / Hour


(minimize) (optimize) (maximize)

Minimize Optimize Manage MAINTENANCE


EQUIPMENT costs PRODUCTION to improve availability

Rebuild Costs Component Lives Application M&R Processes


% A/F Repairs Design Defects Pit Depth Planning & Scheduling
Parts Reuse Application Haul Distance Preventive Maintenance
Parts Price Maintenance Grades Condition Monitoring
Repair Quality Operation Backlog management
Operator Skill Parts Management
Payload Mgmt Repair Management
Cycle Times Component Management
HR/People Development
Performance Evaluation
Continuous Improvement
What areas do we affect ?

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Repair & Maintenance Management
• Machine Lifecycle; How can I develop capabilities
that will lower my risk to obtain optimum life,
availability and utilization?

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Continuation…..

Cost / Hour Cost / Ton Tons / Hour


(minimize) (optimize) (maximize)

Minimize Optimize Manage MAINTENANCE


EQUIPMENT costs PRODUCTION to improve availability

Rebuild Costs Component Lives Application


% A/F Repairs Design Defects Pit Depth
Parts Reuse Application Haul Distance
Parts Price Maintenance Grades
Repair Quality Operation
Operator Skill
Payload Mgmt
Cycle Times

What areas do we affect ?

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Continuation…..
We Must be aligned
with the customer to
Optimum Fleet
Management Strategy

Repair & Maintenance Management First PCR Equipment


Cycle Disposal
Machine Life Cycle
(Based on PCR)

Planned
Scheduled
Downtime Detection Unscheduled Periodic
Repairs
Component
Reasons Routines Repairs Services Replacement
(Major & Minor)
(PCR)
• Vital to minimize/prevent • Who’s in control? • Fixed frequency • Planning window to keep • Frequency determined by
unscheduled stops • Must be minimized • Well known routine condition of machine at component life targets and
Downtime •Frequency; a function of • Negative influence on • Foundation of defined level health
MTBS MTBS, MTTR and efficient/effective • Frequency determined by • Window used for restoring
Hints • Normally performed in Availability maintenance management planning machine to standard
parallel with other • Frequency must be • Starting point of a new
maintenance activities controlled component life cycle

Ability to
Ability to build MTBS, MTTR &
maintain the
Impact On a preventive Maintenance Availability Costs ($)
maintenance
plan Plan Cost ($)
plan

All events reduce asset utilization.

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Continuation…..
Key performance indicators
Equipment management metrics Operations management metrics

• Physical Availability • Total Tons (Production)


• Availability Index • Tons/hour and cost/ton
• Mean time between shutdowns • Fuel consumption
(MTBS) • Payload management
• Mean time to repair (MTTR) • Haul cycle detail
• % Scheduled Downtime
• %Scheduled Events
• Asset utilization
• Maintenance ratio
• Top problems

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Continuation…..
M&R Process Model

Preventive
Predictive
Condition Based
Proactive Maintenance

The M&R model is based on key concepts of Preventive, Predictive or Condition


Based and Proactive Maintenance to achieve our common goal of preserving
the primary function of the equipment at the optimum level of safety, reliability &
cost performing the M&R activities before failure delivering the available hours
to support effectively the production plan of our customers.

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Continuation…..
Process Maps Development – 3 Fundamental Layers

With What

Tools

Who will Do it
People Functions &
Responsibilities

What & How to Do


Processes

Everything starts with the Process … What are we going to Do


and How are we going to Do It.
Business Management

• Machine Lifecycle; What data do I need to manage


my business?

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Continuation…..
Mining Business data and metrics
Availability Productivity Costs

Reliable delivery of Performance as sold from What are the areas that
required or budgeted the fleet. Meeting these both impact and drive the
hours to meet your production targets. cost to the customer to
production targets / goals. Payload / Speed on move material.
Physical / grade TCO
Mechanical Material / Tons Component life
Availability moved / BCM’s Ore Production hours
Utilization through the crusher Fleet utilization
MTBS Cost / Ton Maintenance Ratio
MTTR Strip to Production
Ratio
Yard/Meters Drilled
Continuation…..

Fuel Consumption
Maintenance & Repair
Operator Efficiency
Tires Cycle Times
Operator Wages
Machine Capital
Cost Payload

Residual Value Mechanical


Lubricants Tonne Availability
Utilization

A 5% change in each of the factors results in the above reductions in cost per ton
The green area is if technology is utilized
Replacement, Rebuild, Disposal
• Replacement, Resale, Disposal
• Machine Lifecycle; What should I do with my
assets?

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Continuation…..
Hourly owning cost goes Hourly operating cost goes
down with age. up with age.
It depends on the rate at which residual It depends on the rate at which
market value decreases and the expenditure on repair parts and labor
number of hours worked in a year. increases as the machine ages.

120

100

80
Total cost / total hours

60

C*
40

20

0
0 1 2 3 4 L* 5 6 7 8 9
Total hours
Continuation…..

Maintenance Program
•PM
•Inspections & Monitoring
•Planning & Scheduling
•Repair
MTBS

Age Older
Design More Complex
Application More Severe
& Operation

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Continuation…..
MTBS vs SMU
(Mining Production Equipment)
140
120
MTBS

100
Period
80
Cumulative
60
40
20
0
13000

17000

21000

25000

29000
1000

5000

9000

SMU
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Continuation…..

3.00
How do you measure
deterioration?
2.50 Cost
Reliability
2.00 Performance

Total
1.50 How do you measure
Deterioration inferiority
obsolescence?
1.00 Productivity
Technology
Obsolescence
0.50 Competition

0.00
1 3 5 7 9
What drives your decision?
Time
Continuation…..
What Does This Look Like @ Fleet Level? Long-Term Fleet
Planning example
Provides the customer a high-level, long-term fleet view in relation
to the expected frame life, enabling a Rebuild vs. Replace strategy
793 Fleet Overview

Anticipated ownership period 80,000 Green Orange Red


Anticipated annual utilization 7,100 75 - 89% of Target Life 90 - 100% of Target Life More than 100% of Target Life
Expected hours in the given number of years ahead
Unit Make Model Hours now 1 2 3 4 5 6 7 8
TRK101 CAT 793C 84,893 91,993 99,093 106,193 113,293 120,393 127,493 134,593 141,693
TRK102 CAT 793C 83,037 90,137 97,237 104,337 111,437 118,537 125,637 132,737 139,837
TRK103 CAT 793C 79,411 86,511 93,611 100,711 107,811 114,911 122,011 129,111 136,211
TRK104 CAT 793C 58,000 65,100 72,200 79,300 86,400 93,500 100,600 107,700 114,800
TRK105 CAT 793C 59,000 66,100 73,200 80,300 87,400 94,500 101,600 108,700 115,800
TRK106 CAT 793C 59,870 66,970 74,070 81,170 88,270 95,370 102,470 109,570 116,670
TRK107 CAT 793B 61,000 68,100 75,200 82,300 89,400 96,500 103,600 110,700 117,800
TRK108 CAT 793C 41,598 48,698 55,798 62,898 69,998 77,098 84,198 91,298 98,398
TRK109 CAT 793C 42,587 49,687 56,787 63,887 70,987 78,087 85,187 92,287 99,387
TRK110 CAT 793C 41,258 48,358 55,458 62,558 69,658 76,758 83,858 90,958 98,058
TRK111 CAT 793C 42,000 49,100 56,200 63,300 70,400 77,500 84,600 91,700 98,800
TRK112 CAT 793C 39,212 46,312 53,412 60,512 67,612 74,712 81,812 88,912 96,012
TRK113 CAT 793C 28,000 35,100 42,200 49,300 56,400 63,500 70,600 77,700 84,800
TRK114 CAT 793B 27,413 34,513 41,613 48,713 55,813 62,913 70,013 77,113 84,213
TRK115 CAT 793C 26,800 33,900 41,000 48,100 55,200 62,300 69,400 76,500 83,600
TRK116 CAT 793C 28,410 35,510 42,610 49,710 56,810 63,910 71,010 78,110 85,210

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Continuación…..
What Does This Look Like @ Fleet Level? Rebuild, Repair,
Annual Spending and Hours Replace example
Spend Avg. Ownership Period
$1,800,000 25,000
Customer Issue:
$1,600,000

$1,400,000
20,000 3,000 hr of annual production
required for 2011 and 2012
Annual Spending

Hours per Unit


$1,200,000

15,000
$1,000,000
3,500 hr of annual production
$800,000
10,000
required for 2013, 2014, 2015
$600,000
Only $700K in capex for 2011
$400,000
5,000

$200,000 Advice / Help needed!


$0 $4.9M total spend 0
2010 2011 2012 2013 2014 2015
$3.3M New, $1.6M Rebuilds
Year
Cheapest & Riskiest
Summary Table Unplanned Downtime!

Hours New Rebuild Repair Rebuild 3 most critical


Total Fleet Hours Remaining (Year 5) 44,500 61,548 12,816 trucks in 2011
Avg. Hours Remaing Per Unit 19,294 18,654 6,163 ($675K capex spend)
Total Costs
Replace the same 3
Replacements $ 6,663,648 $ 3,331,824 $ 832,956 trucks in 2012-2014
Capitalized Rebuilds $ - $ 1,575,000 $ 450,000
Expensed Repairs $ - $ - $ 1,000,000 Rebuild least critical
Total Cost $ 6,663,648 $ 4,906,824 $ 2,282,956 truck in 2012 and
Replace in 2015

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Age Fleet “Rules of Thumb”
• Frame strength and integrity

High Production • Current technology/emissions adequate or upgrade


e.g. Dragline,
Shovel, Longwall,
> T HEX
needed?
• Is machine sized for rebuild cost effectiveness?

Production
• Minimum size for a powertrain rebuild 45-50K lbs.
e.g. 797 - 785
994, <200 T HEX
LHD
• Minimum size for a complete rebuild 100K lbs.
• Cost of rebuild
Support • Powertrain rebuild 35-40% of new (dealer)
LTTT, WD, MG,
Power Systems
• Complete rebuild 60-65% of new (dealer)
• Availability of standard or extended warranties
Utility
Construction
Machines on site

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RESUMEN DE LA SESIÓN

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EVALUACIÓN DE LA SESIÓN
• Responda a las preguntas de la evaluación online

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SIGUIENTE SESIÓN
RESPONSABLE: DARÍO FRÍAS
OPERATIONS & PROJECT
TEMA:
MANAGEMENT
INFORMACIÓN • www.cat.com
PREVIA: • www.komatsu.com
• www.atlascopco.com
• www.sandvick.com
• Diapositivas de la unidad 2 del Curso

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Curso: Gestión de Equipo Pesado
Especialidad: Mantenimiento de Maquinaria Pesada
6to Semestre

Profesor: Darío Frías


TECSUP 2018

Mantenimiento de Maquinaria Pesada 36