2514

A practical application of RCM principles at the
Cement Australia Railton plant

by
Dennis Knuckey Maintenance Manager &
Peter Johnson Maintenance Planner
CEMENT AUSTRALIA
Australian
Queensland
Cement
Cement &
P/L
Lime P/L
Cement supply & distribution
Cement & lime supply
in Tas, Vic & NSW
in Qld & NSW
Sales & marketing roles
Manufacturing in
in other states
Gladstone / Rockhampton Qld(1.7Mt)
Manufacturing in Kandos NSW(0.5Mt)

& Railton Tas (1.2Mt)
2
The Process we went

through
The trigger - the Asian crisis 1998 / cement imports 1999 / import parity / $15
challenge
Step 1 = Benchmarked current maintenance performance to
determine whats good
determine what can be improved
set a business target in $s
Step 2 = RCM trial process on no 5 Cement Mill system by Honeywell
Step 3 = find RCM type software and train in the use of for building Reliability Block Diagrams (RBDs) and for both Weibull analysis /
FMECA analysis (Failure Mode Effects and Criticality Analysis)
Step 4 = The actual project

3
STEP 1 = BENCHMARKING
Strategic Industries Research Foundation (Vic) (SIRF) contacted in mid 1998 to

perform a maintenance benchmark of the Railton site which they fed back to us in
November 1998
Their conclusions were -
Existing maintenance systems well defined and quite effective

However plant operating performance being achieved at above normal
maintenance expense
Possible savings in the order of $2.5 M which represents a reduction
from approx 4% ERV to 3% ERV (Equipment Replacement Value)
World best practice for a brand new, green field facility would approach
2.2% to2.5% ERV
Too many people maintaining
Too few resources planning
They recommended we adopt a Reliability Centred Maintenance approach

We set ourselves a target of $2M maintenance cost reduction p.a. within 2 years
Need to do so without adversely affecting annual production for business reasons
4
Step 2 = PILOT STUDY - NO 5 CEMENT MILL

Developed by Honeywell under the guidance of Craig Webb
Down loaded a 12 month period of breakdown data from our CMMS for all
machines in CM5 system and built a typical RBD diagram and showed us
how the FMECA process worked.
Conclusions were System availability was only 87% & 5 machines of the 28 machines in the
system were responsible for more than 80% of the failures
By reducing breakdowns by 50% the system availability would improve to
94%
50% reduction in breakdowns calculated to a direct maintenance savings of
approx $200k p.a
50% reduction in breakdowns would reduce the requirement to run the
smaller no 4 CM (60 tph c.f 130 tph) and save another $200k p.a.
He predicted that we would find this 20/80 rule in machines and in failure
modes throughout the plant and that our maintenance system was not aligned to
recurring failure modes. To test this we looked at breakdown work c.f planned
work from our CMMS.
5
Step 2 = PILOT STUDY - site wide planned /

unplanned work analysis
Planned v Breakdown
work orders
2000
1500
1000
500
-9
Ju 8
n98
Au
g98
O
ct
-9
D 8
ec
-9
Fe 8
b99
Ap
r-9
Ju 9
n99
Au
g99
O
ct
-9
D 9
ec
-9
9
Fe
b00
Ap
r-0
Ju 0
n0
Au 0
g00
O
ct
-0
D 0
ec
-0
0
Fe
b01
Ap
r-0
Ju 1
n0
Au 1
g01
O
ct
-0
D 1
ec
-0
Fe 1
b02
0
Ap
r
number of work orders
2500
Time
Breakdown events
Planned events
CONCLUSIONS:
1/. Planned w ork base w ork orders have decreased by approx. 250 per month
2/. Yet, unplanned w ork orders or events are static at approximately 230 per month
3/. Therefore, the site w ide MTBF is constant. I.e. the random failure rate has not changed
4/. Therefore the planned w ork IS NOT addressing the failures
Step 3 - software - AvSim & RCMCost by

Isograph, UK and represented in Australia by
ARMS Reliability Engineering


Lifetime costs simulated

over 10 years in this
example

Typical Weibull
calculation from
failure data
10
"Bath tub curve" - Weibull
Failure rate f
Beta < 1
Beta = 1
Beta > 1
Random failure
Wear out failure
1
Infancy failure
Gamma
Time
11
Step 4 = The Actual Project
12
How will we do this ?
We have to align our maintenance strategies for poorly performing

machines to address actual failure modes that the machine is
experiencing
We have to challenge the maintenance strategy on machines that
perform well for probable over servicing
To do so, we need to determine which machines to investigate and
what specific failure modes these machines show.
By looking at what we currently do from our planned maintenance
system we can make choices to Delete / Add / Alter / existing pms so that the failure modes are addressed
Test the decision to change the maintenance choice using new Reliability
software
13
How will we do this ?
We have reasonable, historic work order data

The site has been broken up into 4 areas or missions Mining
Raw Milling
Clinkering
Cement / Despatch
We analysed 3 years breakdown work orders and for each major machine
within these 4 areas calculated Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR)
This enables us to calculate Machine Availability (A). Hence we can rate
machines by performance.
By using a pareto approach we will select the worst performing machines in
each area for FAILURE MODE analysis
We then check what our existing maintenance looks for and make the
necessary changes
14
Typical breakdown work order data for a single machine

M AJOR
M ACHINE NO.
WORK
ORDER NO.
WORK ORDER DESCRIPTION
EM PLOYEE
LABOUR
COST
WORK PERFORM ED
MACHINE NO. 1656 = MINE LIM ESTONE FEEDER

1 6 56
539328
CHECK BLOCKED FILTER ALARM IN HYD PUMP - NEW MINE
6 F G1PWM 23
1 6 56
543444
APRON FEEDER JAMMED
6 F G1BRH 22 10 1998 1 LIMESTONE FEEDER JAMMED CLEARED FEEDER AND
1 6 56
543444
APRON FEEDER JAMMED
6 F G1BRH 22 10 1998 2 ADJUSTED REGULATING VALVE TO CLEAR BLOCKAGE
1 6 56
544389
APRONFEEDER WONT RUN.
6 F G1PGM 20 11 1998 1 ADJUSTED PRESSURE TO MAX. 350BAR BUT COULD
1 6 56
544389
6 F G1PGM 20 11 1998 2 NOT MOVE FEEDER. ENDED UP DIGGING FEEDER
1 6 56
544389
6 F G1PGM 20 11 1998 3 OUT WITH EXCAVATOR
1 6 56
544389
6 E G1MRW 30 11 1998 1 ASSISTED FITTER UN-BLOCKING APRON FEEDER
1 6 56
554075
CHECK LOW TONNAGE OUTPUT FROM LIMESTONE FEEDER
6 E G1SKC 14
9 1999 1 CHECKED AND ALL OK ELECTRICALLY. SUSPECT FEED
1 6 56
554075
CHECK LOW TONNAGE OUTPUT FROM LIMESTONE FEEDER
6 E G1SKC 14
9 1999 2 CHUTE BLOCKAGE.
1 6 56
5 F G1PTM
4 2000 1 FOUND THAT LIMESTONE HAD JAMMED APRON FEEDER
3002870 LIMESTONE FEEDER JAMMED.
6 1998 1 CHECKED FILTER LOOKED OK CLEANED OUT ANYWAY
74.16
162.9
377.65
5.4
0
135.5
1 6 56
5 F G1PTM
4 2000 2 ASKED QUARRY PERSONAL TO REMOVE LIMESTONE
1 6 56
5 F G1PTM
4 2000 3 FEEDER.
1 6 56
3002379 NEW MINE APRON FEEDER ZSS TRIP
6 E G1DBC 12
4 2000 1 FEEDER JAMMED
1 6 56
3002379 NEW MINE APRON FEEDER ZSS TRIP
6 E G1DBC 12
4 2000 2 DUG OFF & ALL OK
1 6 56
3003861 1656 APRON FEEDER JAMMED
5 F G1BJB
5 2000 1 OPERATED APRON FEEDER MANUALLY, FEEDER STILL
135.57
1 6 56
5 F G1BJB
5 2000 2 JAMMED, HOPPER HAD TO BE DUG OUT.
1 6 56
3003877 1656 LIMESTONE FEEDER JAMMED
6 F G1GB
5 2000 1 BOOSTED HYDRAULIC PRESSURE
130.39
1 6 56
3003290 LIMESTONE FEEDER TRIPPING ON LOW OIL PRESSURE
5 E G1GMB 29
8 2000 1 FITTER FOUND A BLOCKED VALVE
517.18
1 6 56
3003742 APRON FEEDER TRIPPING ON UNDERSPEED
5 E G1GMB 29
8 2000 1 VALVE FAULT,FITTER CALLED TO REPAI NOW OK.
188.16
1 6 56
3013353 CHECK MULTILIN ALARM ON 1656 LIMESTONE FEEDER
6 E G1SKC 22
1 2001 1 HOT ROOM CAUSED THERMISTER ALARM. RESET WHEN IT CO
1 6 56
3013353 CHECK MULTILIN ALARM ON 1656 LIMESTONE FEEDER
6 E G1SKC 22
1 2001 2 OLED DOWN.
1 6 56
200
541151
CHECK GREASE PUMP CUTTING OUT - NEW MINE
6 E G1DBC 12
8 1998 1 REPLACED EMPTY DRUM. ALL NOW OK.
1 6 56
200
541151
6 E G1DBC 12
8 1998 2 THE ALARMS FOR THIS NEED LOOKING AT. WHEN THE DRUM
1 6 56
200
541151
6 E G1DBC 12
8 1998 3 RUNS EMPTY THE PUMP DISABLES ITSELF AND THE ONLY
8 1998 4 ALARM IS CMD.LOCKED.
64.01
0
124.17
1 6 56
200
541151
6 E G1DBC 12
1 6 56
200
555498
CHECK 1656 GREASE PUMP
6 F G1PWM 1 10 1999 1 REPLACED M/T DRUM
1 6 56
200
555498
CHECK 1656 GREASE PUMP
6 F G1PWM 1 10 1999 2 PUMP TOOK 45MIN TO BUILDUP PRESSURE
1 6 56
200
3001423
MINE APRON FEEDER GREASE PUMP STOPPING
6 E G1DBC 29
2 2000 1 CHECKED BUT FOUND NOTHING
1 6 56
200
3001423
MINE APRON FEEDER GREASE PUMP STOPPING
6 E G1DBC 29
2 2000 2 NEED TO SEE IT IN OPERATION
1 6 56
200
3002888 RELIEF VALVE HOSE ON GREASE PUMP BROKEN -A/FEEDER
5 F G1BJB
4 2000 1 SHORTENED HOSE BY 25MM, FITTED 12.5 S/S TUBE
1 6 56
200
5 F G1BJB
4 2000 2 INSIDE HOSE FOR COMPRESSION OLIVE TO SEAT ONTO,
1 6 56
200
5 F G1BJB
4 2000 3 REFITTED HOSE - TESTED PUMP O.K.
1 6 56
200
3003878 LIMESTONE FEEDER GREASE PUMP NOT WORKING
6 F G1GB
1 6 56
200
3006989 LIMESTONE FEEDER GREASE PUMP CUT OUT
6 F G1PGM 17
7 2000 1 PUMP CUT OUT -BUILT UP PRESSURE BUT HAD'NT
1 6 56
200
6 F G1PGM 17
7 2000 2 CHANGED OVER - CRACKED DISCHARGE LINES , PUT
1 6 56
200
6 F G1PGM 17
7 2000 3 PUMP ON LOCAL AND TEST RAN, CHANGED OVER OK
1 6 56
200
6 F G1PGM 17
7 2000 4 RAN FOR 10MIN CHANGING OVER BOTH WAYS OK
1 6 56
200
3008475 CHECK 1656 GREASE PUMP OUT ON O/L
6 E G1BJE 17
8 2000 1 REPLACED GREASE DRUM AND RESET PUMP.
638.56
321.37
129.17
0
106.14
0
175.45
5 2000 1 REPLACED EMPTY DRUM / PUMP THEN OK
123.94
46.66
1 6 56
200
3008476 CHECK 1656 GREASE PUMP FAULT
5 F G1PLB 17
8 2000 1 CHANGE OVER VALVE WAS STUCK, RELEASED PRESSURE
1 6 56
200
3008476 CHECK 1656 GREASE PUMP FAULT
5 F G1PLB 17
8 2000 2 & IT STARTED TO WORK AGAIN OK.
1 6 56
200
3008809 INSPECT GREASE LINE FAULT ON FEEDER GREASE PUMP
5 F G1BJB 26
8 2000 1 CHECKED GREASE PUMP SYSTEM - CHANGE OVER VALVE
1 6 56
200
5 F G1BJB 26
8 2000 2 STUCK IN ONE POSITION, BLED OFF PRESSURE THEN
1 6 56
200
5 F G1BJB 26
8 2000 3 RESTARTED.
1 6 56
200
3008622 HIGH DIFFERENTIAL PRESSURE ON PUMP.
6 E G1NPR
6 10 2000 1 RELEASED PRESSURE OUT OF GREASE LINES.
1 6 56
200
3008622 HIGH DIFFERENTIAL PRESSURE ON PUMP.
6 E G1NPR
6 10 2000 2 SYSTEM STARTED WORKING OK.
1 6 56
200
3010936 CHECK LIMESTONE FEEDER GREASE PUMP FAULT.
6 E G1SKC 10 10 2000 1 TOOK GREASE LINE OFF AND CHANGED OVER PRESSURE
1 6 56
200
3010936 CHECK LIMESTONE FEEDER GREASE PUMP FAULT.
6 E G1SKC 10 10 2000 2 SWITCH. RESET OK.
NO EVENTS
23
0
24.31
199.36
15
0
35.19
0
3715.24
MACHINE NO. 3030 = STACKER
PURCHASES COST
STORES COST
EMP. LABOUR COST
AVAILABILITY
MTTR
MTBF
OPERATING EST.HOURS
HOURS
% OF CUMULATIVE TOTAL
EVENTS
% OF TOTAL EVENTS
NO. OF B/DOWN OR
UNPLANNED WORK ORDERS
MACHINE DESCRIPTION
A Summary of Breakdown data for the Mine Section
109
32.15%
32.15%
539.595
4500
41
4.95
0.8929
59424.15
3107.51
16369.08
MACHINE NO. 1658 = MINE CRUSHER
53
15.63%
47.79%
665.23
4500
85
12.55
0.8712
56404.89
158039.71
13765.54
MACHINE NO. 1660 = MINE CRUSHER DISCHARGE CONVEYOR
49
14.45%
62.24%
215.785
4500
92
4.40
0.9542
15052.62
30437.71
14803.79
MACHINE NO. 1656 = MINE LIMESTONE FEEDER
23
6.78%
69.03%
45.095
4500
196
1.96
0.9901
3715.24
80.97
119.4
MACHINE NO. 3025 = STACKER FEED CONVEYOR
19
5.60%
74.63%
30.4
4500
237
1.60
0.9933
2216.94
962.3
95
MACHINE NO. 1675 = MINE TRUNK CONVEYOR
17
5.01%
79.65%
26.625
4500
265
1.57
0.9941
2246.95
1237.09
1067.42
MACHINE NO. 1657 = MINE LIMESTONE FEEDER SPIILAGE CONVEYOR
16
4.72%
84.37%
40.04
4500
281
2.50
0.9912
3207.34
160.35
1961.89
MACHINE NO. 3022 = ANALYSER INLET CONVEYOR
16
4.72%
89.09%
19.59
4500
281
1.22
0.9957
1466
1563.48
3757.92
MACHINE NO. 1661 = MINE CRUSHER DISCHARGE SPILLAGE CONVEYOR
10
2.95%
92.04%
28.27
4500
450
2.83
0.9938
2431.46
1500.22
128.2
MACHINE NO. 1682 = MINE TRANSFER CONVEYOR
1.77%
93.81%
14.28
4500
750
2.38
0.9968
1106.54
611.87
MACHINE NO. 1652 =MINE CRUSHER MAINTENANCE CRANE
1.18%
94.99%
6.02
4500
1125
1.51
0.9987
262.44
1780.2
MACHINE NO. 1680 = MINE TRANSFER TOWER
1.18%
96.17%
14.765
4500
1125
3.69
0.9967
927.68
312.76
1127.54
MACHINE NO. 1699 = MINE CRUSHER OTHER
0.88%
97.05%
2.93
4500
1500
0.98
0.9993
135.87
36
MACHINE NO. 3023 = CROSSBELT ANALYSER
0.88%
97.94%
10.9
4500
1500
3.63
0.9976
339.74
MACHINE NO. 1650 = MINE STRUCTURE
0.59%
98.53%
1.12
4500
2250
0.56
0.9998
36.2
MACHINE NO. 1655 = MINE LIMESTONE HOPPER
0.59%
99.12%
2.45
4500
2250
1.23
0.9995
118.17
14
MACHINE NO. 1662 = MINE CRUSHER DUST COLLECTOR
0.59%
99.71%
3.25
4500
2250
1.63
0.9993
151.35
470.89
MACHINE NO. 1663 = MINE CRUSHER AIR COMPRESSOR
0.29%
100.00%
4.32
4500
4500
4.32
0.9990
208.73
12.19
16
17
18
Forming Failure Mode data from the work order data for a single
machine - sheet 1
Empl $
Str
1 6 56
0 139454 COMMISSION NEW T.P.HOUR INDICATOR - MINE
1 E G1TER
28
5 1998
1 JOB DONE BY INSTRUMENT DEPT.
1 6 56
0 539328 CHECK BLOCKED FILTER ALARM IN HYD PUMP - NEW MINE
6 F G1PWM 23
6 1998
1 CHECKED FILTER LOOKED OK CLEANED OUT ANYWAY
1 6 56
0 539544 NEW MINE APRON FEEDER - TWO WEEKLY INSP
7 F G1PLB
14
7 1998
1 COMPLETED AS PER INSTRUCTION, NOTHING UNUSUALL
1 6 56
7 F G1BJM
27
7 1998
1 1656C GREASE PUMP IS CHANGING OVER AT LESS THAN
159.55
1 6 56
7 F G1IDS
10
8 1998
1 APRON FEEDER WAS JAMMED BUT ALL LOOKED OK
222.64
22.28
1 6 56 200 541151 CHECK GREASE PUMP CUTTING OUT - NEW MINE
6 E G1DBC
12
8 1998
1 REPLACED EMPTY DRUM. ALL NOW OK.
124.17
1 6 56
7 F G1BJB
25
8 1998
1 ONLY HAD SHORT AMOUNT OF TIME TO INSPECT APRON-
1 6 56
7 F G1JJL
14
9 1998
1 6 56
7 F G1BJB
28
9 1998
1 6 56
7 F G1BJB
12 10 1998
1 6 56
6 F G1BRH
22 10 1998
1 LIMESTONE FEEDER JAMMED CLEARED FEEDER AND
1 6 56
7 F G1IRS
26 10 1998
1 CHECKED AS PER SCHEDULE O/K
138.28
1 6 56
7 F G1PGM
16 11 1998
1 CHECKED AS PER METHOD SHEET OK
102.32
29
1 6 56
7 F G1BJB
16 11 1998
1 CHECKED AS PER SCHEDULE. COULD NOT RUN APRON
100.96
1 6 56
0 544389 APRONFEEDER WONT RUN.
6 F G1PGM
20 11 1998
1 ADJUSTED PRESSURE TO MAX. 350BAR BUT COULD
377.65
1 6 56
7 F G1BJB
30 11 1998
1 INSPECTED AS PER SCHEDULE - FOUND SLIDE RAIL LUBE
391.1
1 6 56
7 F G1JH
14 12 1998
1 CLEANED HYDRAULIC POWER PACK UP AND SWEPT ROOM
421.88
1 6 56
1 6 56

7 F G1GKH
7 F G1JJL
22
8
1 ONLY VISUAL INSPECTION CARRIED OUT DUE TO HOPPER

1 CHEKED ALL OKAY.APRON FEEDER FULL COULD TEST RUN
104.23
161.5
0
0
1 6 56
7 F G1GAW 22
3 1999
1 CHECKED AND OK
193.04
81.2
1 6 56
7 F G1JMH
4 1999
1 CHECKED AS PER METHOD 0128. FOUND THE APRON FEEDER
467.14
1 6 56
7 F G1BRH
19
4 1999
1 HAVE CHANGED GREASE DRUM ON 1656C PUMP.FITTED
375.97
1 6 56
7 F G1GAW 31
5 1999
1 ALL CHECKED AND OK
291.03
1 6 56
0 550751 REPAIR FEEDER ACCESS DOORS
1 F G1PWM
6 1999
1 TEMP REPAIR ONLY CHANGED TO M/SHUTDOWN W/O
102.83
10.18
1 6 56
7 F G1JJL
11
6 1999
1 CHECKED ALL OKAY.
105.62
35
1 6 56
0 551300 REPAIR GUARD AT HEAD END OF APRON FEEDER.
1 F G1DEJ
29
6 1999
1 WELDED LUGS BACK ONTO SIDE OF BIN TO BOLT GUARD TO
278.16
68.47
1 6 56
7 F G1GB
30
7 1999
1 CHECKED AS PER W/O----OK
258.41
1 6 56
7 F G1BRH
8 1999
1 HAVE INSPECTED HYDRAULICS AS REQUIRED.OK.
293.49
7.39
1 6 56
7 F G1PGM
20
8 1999
1 HYDRAULIC POWERPACK AND LINES OK - SLIGHT LEAK ON
293.49
1 6 56
0 553792 CUT OFF REMAINS OF DAMAGED RIPPER BARS ON FLIGHTS 1 F G1PTM
20
8 1999
1 CUT OUT DAMAGE RIPPER BARS AND GRIND FLIGHTS
127.09
29.54
1 6 56
0 550751 REPAIR FEEDER ACCESS DOORS
1 F G1BJM
30
8 1999
1 REPAIRED ALL ACCESS DOORS TO LIMESTONE FEEDER.
308.49
30.53
1 6 56
0 554075 CHECK LOW TONNAGE OUTPUT FROM LIMESTONE FEEDER
6 E G1SKC
14
9 1999
1 CHECKED AND ALL OK ELECTRICALLY. SUSPECT FEED
1 6 56 200 555498 CHECK 1656 GREASE PUMP
6 F G1PWM
2 1999
3 1999
1 10 1999
6.2
74.16
28.03
1 CHECKED AS REQUIRED ALL OKAY
122.62
11.35
1 INSPECTED AS PER SCHEDULE. NO PROBLEMS FOUND ALL
286.81
1 INSPECTED AS PER SCHEDULE, ALL O.K.
101.68
7.7
162.9
1 REPLACED M/T DRUM
5.4
129.17
19
Forming Failure Mode data from the work order data for a single machine
- sheet 2
Com ponent Function
Functional Failure
Apron Feeder
Apron Feeder To provide motive pow er to f eeder
Failure Mode
Start date Fail date
Days run Op Hrs 6.3
Effects
Probable cause
Alarm
Blocked filter
1-Apr-98
23-Jun-98
83
519 S
Grease drum empty
Alarm
Empty grease drum
1-Apr-98 12-Aug-98
133
831 F
Feeder jamming
Feeder trips Rock jamming f eeder
1-Apr-98
204
1275 S
Feeder jamming
Feeder trips Rock jamming f eeder 22-Oct-98 20-Nov-98
TPH Indicator
Fails to provide motive pow er
Oil f ilter failure
7
7
Grease pump
7
Grease pump To provide adequate grease supply
Feeder jamming
Fails to supply grease at all
7
7
7
7
Apron Feeder To transport material to crusher at design rate Fails to transport material at all
22-Oct-98
7
7
7
29
181 S
1-Apr-98 30-Nov-98
243
1519 S
High oil temp. Blocked cooler
1-Apr-98 14-Dec-98
257
1606 S
Spillage
1-Apr-98
23-Jun-98
83
519 S
30-Nov-98
Fails to supply adequate grease Change over valve failure No grease
Apron Feeder To provide hydraulic oil cooling
Fails to provide hydraulic oil cooli Oil cooler failure
7
7
Valve sticking
Bearing housing w edge
7
7
7
Grease drum empty
7
Apron Feeder To contain spillage
Fails to contain spillage
Access door failure
Door damaged
7
Apron Feeder
Guard repairs
7
Fails to supply adequate grease Change over valve failure No grease
Fails to supply adequate grease Grease line f ailure
Apron Feeder To transport material to crusher at design rate Fails to transport at design rate
Ripper bar f ailure
Apron Feeder To contain spillage
Access door failure
Fails to contain spillage
Valve sticking
6-Aug-99
249
1556 S
1-Apr-98 20-Aug-99
506
3163 S
Bars damaged
1-Apr-98 20-Aug-99
506
3163 S
Door damaged
23-Jun-98 30-Aug-99
433
2706 F
Grease spilla Loose f ittings

Spillage
Feeder jamming
Feeder trips Rock jamming f eeder 20-Nov-98 14-Sep-99
298
1863 S
Grease drum empty
Alarm
415
2594 F
Fails to supply grease at all
Empty grease drum
12-Aug-98
1-Oct-99
20
Forming Failure Mode data from the work order data for a single machine sheet 3
Effects
Probable cause
Access door failure
Spillage
Door damaged
1-Apr-98 23-Jun-98
83
519 S
Access door failure
Spillage
Door damaged
23-Jun-98 30-Aug-99
433
2706 F
Apron feeder flight failure
Spillage
Bent / damaged
1-Apr-98 21-Dec-99
629
3931 F
Apron feeder flight failure
Spillage
Bent / damaged
21-Dec-99 13-Dec-00
358
2238 F
Skirt failure
Spillage
Wear / abrasion
1-Apr-98 21-Aug-00
873
5456 S
Skirt failure
Spillage
Wear / abrasion
Ripper bar f ailure

Ripper bar f ailure
Start date Fail date
Days run Op Hrs
6.25 RCM NO.
Failure Mode
21-Aug-00 23-Mar-01
214
1338 S
Bars damaged
1-Apr-98 20-Aug-99
506
3163 S
Bars damaged
20-Aug-99 21-Dec-99
123
769 F
1-Apr-98 22-Oct-98
204
1275 F
Feeder jamming
Feeder trips
Rock jamming feeder
Feeder jamming
Feeder trips
Rock jamming feeder
22-Oct-98 20-Nov-98
29
181 F
Feeder jamming
Feeder trips
Rock jamming feeder
20-Nov-98 14-Sep-99
298
1863 F
Feeder jamming
Feeder trips
Rock jamming feeder
14-Sep-99
7-Apr-00
206
1288 F
Feeder jamming
Feeder trips
Rock jamming feeder
7-Apr-00 12-Apr-00
31 F
Feeder jamming
Feeder trips
Rock jamming feeder
12-Apr-00
3-May-00
21
131 F
ETA BETA
CORRECTIVE
8.00 28.73
1656-11A2
1.34 38.26 3427.47 3 0.90 30.59 30
1656-11A3
1.34 44.90
1656-12A1
8.00 31.77 1784.76 2 0.60 30.59 30
Feeder trips
Rock jamming feeder
3-May-00
8-May-00
31 F
1656-12B1
Oil cooler failure
High oil temp.
Blocked cooler
1-Apr-98 14-Dec-98
257
1606 S
1656-21A1
1656-22A1
1.73 42.87
0.00
8.21 42.93
0.00
Alarm
Blocked filter
1-Apr-98 23-Jun-98
83
519 S
Valve failure
No oil flow
Blocked valve
1-Apr-98 13-Apr-00
743
4644 F
Valve failure
No oil flow
Blocked valve
13-Apr-00 29-Aug-00
138
Hydraulic pressure transducer

Hydraulic pump
Hydraulic pump
863 S
1656-22A2
29-Jan-01
1656-22A3
1-Jun-95
S
S
Hydraulic pump
Multilin f ailure
Alarm
Room temp. too high
1-Apr-98 21-Jan-01
Change over valve failure
No grease
Valve sticking
No grease
Valve sticking
30-Nov-98
No grease
Valve sticking
No grease
Valve sticking
No grease
1-Apr-98 30-Nov-98
1026
1656-22A4
6413 S
1656-31A1
243
1519 F
6-Aug-99
249
1556 F
6-Aug-99
17-Jul-00
346
2163 F
17-Jul-00
4-Aug-00
18
113 F
Valve sticking
4-Aug-00 17-Aug-00
13
81 F
No grease
Valve sticking
17-Aug-00 26-Aug-00
56 F
No grease
Valve sticking
26-Aug-00
6-Oct-00
41
256 F
No grease
Valve sticking
6-Oct-00 10-Oct-00
25 F
INSPECTIONS
1656-11A1
Feeder jamming
Oil filter failure
PREVENTIVE
1656-41A1
617
0.00 2 0.60 30.59 30
0.57 3.24 41.75 17.06
0.90 30.59 30
13.62 31.00
0.00
1.37 46.72
0.00
0.00 19.08 31.75
0.6 3.16 38.72 13.00
0.00 1
0.30 30.59 30
57.04 31.72
594
765.24 3
8.00 37.33
932.22 1
509.11 3 0.90 30.59 30

310.74 3
10.40 1 0.60 30.59 30
21
22
Mine Crusher Apron Feeder
85 t capacity haul trucks
400 tonnes capacity hopper
Matl into crusher

17 metres
Hydraulic drive
Average capacity = 200 t
Lubricated impact bars
Apron feeder
Coefficients of friction:
Steel on steel lubricated = 0.05
Steel on stell dry = 0.2
Steel on steel limiting friction = 0.3
Frictional drag:
Lubricated = 10 tonnes
Dry = 40 tonnes
Stalled = 60 tonnes
23
24
25
26
27
28
29
30
Documenting the optimising process
Maintenance Strategy DecisionTree

Select the failure mode and have its root cause known
Step 1
Are any of the current maintenance inspections, PM's or schedules aimed at the
failure mode?
If not then eliminate the existing maintenance strategies
If so is it aimed at root cause or does it need modifying?
Yes
Retain
Step 2
Of those remaining inspections, PM's or schedules tied to this machine are any
adding value to detecting failure modes? If not then eliminate.
Yes
Retain
Step 3
Can the failure mode be tolerated?

So what if it occurs?
Is the risk acceptable?
Yes
Run to failure
Step 4
Can the onset of the failure mode be detected?

Is there a potential failure condition I can detect?
Is the p-f interval long enough for response?
Yes
Specify a predictive maintenance task
Step 5
Can the failure mode be prevented from acting?

Can I predict a wear out age?
Will sufficient items last to wear out?
Yes
Specify a preventive maintenance task
Step 6
Can instrumentation pick up an alarm condition

Will I have time to repsond?
Yes
Install a condition monitoring system
Step 7
Is the failure mode hidden?

Will an operator know if it fails in normal operation?
Yes
Specify hidden failure finding task
Step 8
Select the best strategy

Does it meet your goals and objectives?
Yes
Implement
No
Change design - capital solution
31
Documenting the optimising process
As is costs
Optimised costs
GREASE PUMP
Maintenance strategy
1656-41A1 Change over valve failure

$482
594 Yes
Corrective
Yes
$146
6843 Yes
Preventive
Nil
$441
228 Yes
$0
Nil
50%
$241
Prepared to run to failure with new Woerner lube system
$0
Inspections
Nil
$0
Remove inspection schedules
On condition
Nil
$0
Capital expediture to replace grease pump which is unreliable & is causing
TOTAL $1,069
$241 TOTAL
$828 a large majority of jamming problems
1656-41A2 Grease line failure

$81
6843 Yes
$0
Nil
$132
228 Yes
$0
TOTAL
Nil
Corrective
Yes
Preventive
Nil
Inspections
Yes
On condition
Nil
50%
$50
20
$115
$0
$0
$213
$165 TOTAL
Keep as part of walk around inspection

1656-41B1 Grease drum empty

$523
1589 Yes
$0
Nil
$132
228 Yes
$0
TOTAL
Nil
Corrective
Yes
Preventive
Nil
Inspections
Yes
On condition
Nil
$656
50%
$188
$0
40 hrs
$172
$0
$360 TOTAL
New Woernersystem has its own supplementary reservoir of approx 8 litres capacity. Hence we can
schedule drum changes on alarm without stopping the plant.
Keep as part of a visual schedule check by Shane Dennis 2 weekly
1656-41B2 Grease pump failure

$0
Nil
Corrective
Nil
$0
$0
Nil
Preventive
Nil
$0
$119
3422 Yes
$0
TOTAL
Nil
$119
Inspections
Nil
$0
On condition
Nil
$0
$0 TOTAL
Prepared to run to failure as new system very reliable and well protected

32
Project control spreadsheet
Summary of Project Development YEM99-2004

Section
Cement
Mining
Raw milling
Clinkering
Total
machines to be
investigated
65
9
27
33
YEM 99-2004
134
Original YEM99-01
79
Models
completed
FMECA
ready
65
9
27
33
57
9
21
22
134
100.0%
79
109
81.3%
79
Review
completed
& initiated
37
4
16
9
66
49.3%
65
Completed
27
0
8
4
39
29.1%
49%
33

E L E C T R IC A L
AREA
LAB. & M AT.
F IT T IN G
HOURS
LAB. & M AT.
S E R V IC E S
HOURS
LAB. & M AT.
HOURS
LAB. & M AT. HOURS
$ 5 ,1 0 5
113
$ 1 3 ,5 3 7
278
$0
S a v i n g s t a r g e t f it t i n g = 1 6 % o f 2 5 0 0 h r s
R A W M IL L IN G
$ 2 7 ,7 2 2
616
$593
14
$0
C L IN K E R IN G
$ 2 1 ,3 6 0
475
$0
CEMENT
$ 3 5 ,9 2 8
798
$0
F IX E D
$ 2 2 ,9 6 7
510
$ 1 1 3 ,0 8 2
2 ,5 1 3
M IN E
TOTALS
$ 1 4 ,1 3 0
$0
292
$0
$ 1 2 7 ,2 1 2
2 ,8 0 5
$ 1 ,0 4 2 ,7 1 4
5 ,1 9 9
M a c h in e s w ith L o w M e a n T im e B e tw e e n F a ilu r e - C U M U L A T IV E A N N U A L IS E D C O S T S A V IN G S
Y E M 9 9 -0 3
b y r e d u c in g fa ilu r e m o d e s
E L E C T R IC A L
AREA
LAB. & M AT.
F IT T IN G
HOURS
LAB. & M AT.
S E R V IC E S
HOURS
LAB. & M AT.
HOURS
M IN E
$ 2 3 ,3 1 9
104
$ 1 2 6 ,5 5 9
633
$ 3 ,3 1 9
19
R A W M IL L IN G
$ 1 3 ,7 7 7
61
$ 2 3 3 ,3 4 0
1 ,1 6 7
$ 1 3 ,7 7 7
79
$ 1 ,2 1 5
$ 1 2 1 ,1 1 3
606
$ 1 ,2 1 5
$ 3 4 ,6 4 0
154
$ 4 5 2 ,7 8 0
2 ,2 6 4
$ 1 7 ,6 6 0
101
$ 7 2 ,9 5 1
324
$ 9 3 3 ,7 9 2
4 ,6 6 9
$ 3 5 ,9 7 1
206
C L IN K E R IN G
CEMENT
NON AREA
TOTALS
T o ta l H ig h M T B F s a v in g s =
T o ta l L o w M T B F s a v in g s =
$ 1 2 7 ,2 1 2
$ 1 ,0 4 2 ,7 1 4
T o ta l s a v in g s =
T o ta l m a n h o u rs =
$ 1 ,1 6 9 ,9 2 6
8 ,0 0 3
34
Description
Base Year
YEM99 - 01
YEM02
YEM03
YED2003
Note: Anything over 1% is highly significant
Unavailability Unavailability Unavailability Unavailability
Mining
MACHINE NO. 1655 = MINE LIMESTONE HOPPER
MACHINE NO. 1657 = MINE LIMESTONE FEEDER SPIILAGE CONVEYOR
MACHINE NO. 1658 = MINE CRUSHER
MACHINE NO. 1660 = MINE CRUSHER DISCHARGE CONVEYOR
MACHINE NO. 1661 = MINE CRUSHER DISCHARGE SPILLAGE CONVEYOR
MACHINE NO. 1662 = MINE CRUSHER DUST COLLECTOR
MACHINE NO. 1663 = MINE CRUSHER AIR COMPRESSOR
MACHINE NO. 1675 = MINE TRUNK CONVEYOR
MACHINE NO. 1680 = MINE TRANSFER TOWER
MACHINE NO. 1682 = MINE TRANSFER CONVEYOR
MACHINE NO. 1683 = MINE TRANSFER DUST COLLECTOR
MACHINE NO. 1698 = MINE MCC
MACHINE NO. 3022 = ANALYSER INLET CONVEYOR
MACHINE NO. 3023 = CROSSBELT ANALYSER
MACHINE NO. 3025 = STACKER FEED CONVEYOR
MACHINE NO. 3030 = STACKER
54.80%
0.10%
8.93%
1.37%
26.26%
7.51%
0.62%
0.17%
0.04%
1.11%
0.41%
0.31%
0.00%
0.00%
0.97%
0.13%
1.49%
10.30%
44.47%
0.31%
4.53%
0.56%
30.79%
2.96%
0.09%
0.00%
0.02%
1.20%
0.04%
0.35%
0.00%
0.00%
0.54%
0.13%
0.14%
4.27%
34.33%
0.11%
3.13%
4.05%
11.17%
7.96%
0.45%
0.00%
0.00%
0.70%
0.00%
0.00%
0.00%
0.00%
0.78%
0.27%
0.00%
6.46%
33.50% Improved 39%

1.80%
1.01%
Lube system upgraded
0.53%
20.17%
Broken shafts
4.03%
0.00%
0.30%
0.00%
0.20%
Tail end zero speed
0.00%
0.08%
0.08%
0.19%
1.36%
0.44%
0.56%
3.00%
Improved but need more
35

Description
Base Year
YEM99 - 01
YEM02
YEM03
YED2003
Note: Anything over 1% is highly s
CM5
MAJOR MACHINE 6100 = C.M.5. BUILDING
MAJOR MACHINE 6105 = C.M.5. DRIVE MOTOR
MAJOR MACHINE 6112 = C.M.5. MAIN GEARBOX
MAJOR MACHINE 6115 - C.M.5. AUXILLARY DRIVE
MAJOR MACHINE 6122 = C.M.5. BALL MILL
MAJOR MACHINE 6125 = CM5 SCHENCK MULTICONT CONTROLLER
MAJOR MACHINE 6130 = C.M.5. CLINKER BIN
MAJOR MACHINE 6132 = C.M.5. GYPSUM BIN
MAJOR MACHINE 6133 = C.M.5. LIMESTONE BIN
MAJOR MACHINE 6140 = C.M.5. CLINKER WEIGHFEEDER
MAJOR MACHINE 6141 = C.M.5. LIMESTONE WEIGHFEEDER
MAJOR MACHINE 6142 = CM5 GYPSUM WEIGHFEEDER
MAJOR MACHINE 6143 - C.M.5. LIMESTONE CONVEYOR
MAJOR MACHINE 6144 = C.M.5. MILL FEED CONVEYOR
MAJOR MACHINE 6146 = C.M.5. BUCKET ELEVATOR
MAJOR MACHINE 6150 = C.M.5. SEPERATOR
MAJOR MACHINE 6158 = CM5 DUST CYCLONE
MAJOR MACHINE 6159 = C.M.5. DUST CYCLONE FAN
MAJOR MACHINE 6160 = C.M.5. LURGI PROCESS FILTER
MAJOR MACHINE 6161 = C.M.5. LURGI FILTER EXHAUST FAN
MAJOR MACHINE 6165 = C.M.5. IBAU PUMP & DOME VALVES
MAJOR MACHINE 6166 = C.M.5. TWO WAY VALVES
MAJOR MACHINE 6167 = C.M.5. COMPRESSOR
MAJOR MACHINE 6170 = C.M.5. ANCILLARY DUST COLLECTOR
MAJOR MACHINE 6198 = MCC61
10.46%
11.23%
1.87%
0.07%
0.17%
0.02%
2.23%
1.51%
0.00%
0.09%
0.02%
0.00%
0.34%
0.08%
0.00%
0.00%
0.30%
1.50%
0.33%
0.00%
0.04%
0.65%
1.20%
1.67%
0.05%
0.12%
0.05%
0.00%
0.04%
0.10%
0.21%
0.20%
4.89%
0.00%
0.22%
0.00%
0.00%
0.39%
0.13%
0.00%
0.00%
0.16%
2.70%
0.19%
0.00%
0.02%
0.51%
0.05%
1.33%
0.01%
0.00%
0.06%
0.00%
0.02%
0.19%
0.00%
0.01%
0.10%
0.00%
0.05%
0.00%
0.00%
0.16%
0.00%
0.00%
0.03%
0.17%
0.24%
0.35%
0.00%
0.00%
0.09%
0.09%
0.33%
0.00%
0.02%
0.00%
0.00%
4.90% Improved 53%

0.03%
0.05%
0.00%
0.00%
0.12%
0.00%
0.06%
0.00%
0.00%
0.81%
0.24%
0.00%
0.03%
0.07%
1.07%
0.55%
0.00%
0.07%
0.06%
0.03%
1.24%
0.00%
0.32%
0.00%
0.14%
Belts -Local supplied belts
Grit return dust. Feed chu

Belt failure caused this
Replaced rotor Jan 2003
Holed front blast plate

Impeller / NDE brg
Includes Dome valves
36

Description
Base Year
YEM99 - 01
YEM02
YEM03
YED2003
Z and Z1 Silos
MAJOR MACHINE 6816 = Z. SILO
MAJOR MACHINE 6820 = Z. SILO DUST COLLECTOR
MAJOR MACHINE 6825 = Z. SILO AERATION
MAJOR MACHINE 6830 = IBAU PUMP
MAJOR MACHINE 6840 = LOADING HOSES Z & Z1 SILO
MAJOR MACHINE 6845 = Z.SILO DISCH. AIRSLIDE TO PUMP 6830
MAJOR MACHINE 6850 = DUST COLLECTOR ON PUMP 6830
MAJOR MACHINE 6860 = IBAU PUMP
MAJOR MACHINE 6875 = Z SILO DISCHARGE A/SLIDE TO PUMP 6860
MAJOR MACHINE 6877 = CEMENT LINES Z & Z1 SILOS
MAJOR MACHINE 6878 = CONTROL PLC & COMPUTER
MAJOR MACHINE 6880 = DUST COLLECTOR FOR PUMP 6860
MAJOR MACHINE 6885 = Z1 SILO
MAJOR MACHINE 6886 = Z1 SILO ROOF D/COLLECTOR
MAJOR MACHINE 6887 = Z1 SILO AERATION & CONT.AIR
MAJOR MACHINE 6888 = Z1 SILO IBAU PUMP
MAJOR MACHINE 6889 = Z1 SILO DISCH. AIRSLIDE TO PUMP 6888
MAJOR MACHINE 6890 = Z1 DUST COLLECTOR ON PUMP 6888
MAJOR MACHINE 6891 = Z1 IBAU PUMP
MAJOR MACHINE 6892 = Z1 DISCH.AIRSLIDE TO PUMP 6891
MAJOR MACHINE 6893 = DUST COLLECTOR ON PUMP 6891
MAJOR MACHINE 6894 = Z1 SILO VENT FAN
MAJOR MACHINE 6895 = Z1 CONTROL PLC & COMPUTER
MAJOR MACHINE 6896 = ROAD TRUCK SYSTEM
20.49%
33.99%
12.62%
0.45%
0.13%
1.94%
2.91%
2.34%
0.70%
0.04%
3.90%
0.10%
2.02%
1.82%
0.40%
0.26%
0.01%
0.45%
0.71%
0.41%
0.19%
1.53%
0.04%
0.01%
0.00%
0.62%
0.00%
0.00%
0.63%
0.87%
0.00%
2.10%
2.76%
1.46%
0.21%
11.86%
0.76%
1.54%
0.17%
0.05%
1.06%
0.37%
0.95%
1.09%
0.08%
0.20%
8.24%
0.10%
0.09%
0.00%
0.05%
0.00%
0.00%
0.01%
0.00%
0.00%
0.47%
0.40%
0.12%
0.00%
0.02%
0.00%
0.00%
0.00%
0.00%
0.18%
6.00%
0.00%
1.33%
0.00%
0.00%
0.52%
0.00%
0.00%
0.00%
0.00%
3.55%
0.00%
7.90% Improved by 61%

0.58%
0.00%
0.00%
4.93%
0.01%
0.01%
0.00%
0.00%
0.01%
0.00%
0.24%
0.34%
0.09%
0.02%
0.00%
0.31%
0.85%
0.00%
0.01%
0.00%
0.40%
0.00%
0.04%
0.02%
0.00%
Significant impr. Due to m
Significant impr. Due to m
Fixed. Was throwing belts
37

Description
Base Year
YEM99 - 01
Unavailability
Rail Bulk
MAJOR MACHINE 6740 = S. SILO
MAJOR MACHINE 6745 = S. SILO DUST COLLECTOR
MAJOR MACHINE 6748 = S SILO AERATION SYSTEM
MAJOR MACHINE 6749 = T SILO AERATION SYSTEM
MAJOR MACHINE 6752 = CONTROL AIR COMPRESSOR
MAJOR MACHINE 6755 = S. SILO DISCH. AIRSLIDES
MAJOR MACHINE 6756 = S. SILO LOADING CHUTES
MAJOR MACHINE 6757 = T. SILO DISCH. AIRSLIDES
MAJOR MACHINE 6758 = T. SILO LOADING CHUTES
MAJOR MACHINE 6760 = T. SILO
MAJOR MACHINE 6761 = S SILO LOADING CHUTE VIBRATORS
MAJOR MACHINE 6763 = T SILO LOADING CHUTE VIBRATORS
MAJOR MACHINE 6765 = T. SILO DUST COLLECTOR
MAJOR MACHINE 6770 = S. SILO TRAIN LOADING D/COLLECTOR
MAJOR MACHINE 6772 = T. SILO TRAIN LOADING D/COLLECTOR
MAJOR MACHINE 6776 = S. SILO WEIGHBRIDGE
MAJOR MACHINE 6778 = T. SILO WEIGHBRIDGE
MAJOR MACHINE 6797 = WAGON DOOR HYD. POWER PACK
MAJOR MACHINE 6798 = WAGON I.D. & SUPERVISORY SYSTEM
YEM02
YEM03
YED2003
Unavailability Unavailability Unavailability
14.80%
14.69%
19.61%
12.62%
0.80%
0.21%
0.12%
0.00%
0.01%
1.07%
3.39%
0.36%
2.47%
0.80%
0.00%
0.00%
0.14%
1.40%
0.42%
2.33%
0.69%
0.30%
0.10%
0.21%
0.09%
0.06%
0.00%
0.06%
0.05%
1.97%
5.07%
0.38%
3.81%
0.00%
0.00%
0.00%
0.02%
0.63%
0.47%
0.18%
0.56%
0.00%
0.04%
1.28%
2.31%
0.00%
0.00%
0.08%
0.00%
3.39%
4.33%
1.26%
2.97%
0.59%
0.00%
0.00%
0.09%
0.83%
3.68%
0.07%
0.00%
0.00%
0.00%
0.02%
0.09%
0.03%
0.00%
0.01%
0.00%
0.13%
3.69%
2.88%
1.44%
0.29%
0.00%
0.00%
0.04%
1.37%
1.03%
0.07%
0.09%
1.09%
0.07%
0.28%
38
What went well
Original data collection of breakdown work orders enabling the quick analysis by
pareto to identify machines with low or high MTBF.
For the first time we have machine availability measures across the entire site.
Sorting and filtering data to produce the Failure Mode information needed to
populate both AvSim and RCMCost software models.
The development of the optimising spreadsheets which capture the actual As Is
costs and the simulated future Optimised costs and the proposed maintenance
strategy changes.
Using AvSim and RCMCost software models to assist in the justification of Capital
Expenditure where this was the chosen strategy.
Using RCMCost field data set numbers to
link model spare parts, Weibull data sets and spreadsheet identification of
failure modes.
to link to future failure work orders as the failure mode for each specific
machine. This will speed up the process of linking work orders to machines to
specific failure modes.
Using a controlled structure to trap costs and project progress for upward
reporting of project savings and major changes to existing plant.
Cost reduction, increased availability and reduced operational costs.
39
What went not so well
Work order data quality - estimate only 70% accurate

Recorded history of work done - from nothing to volumes
Stores issues not reported on the work order
Use of the wrong work order in transactions
Multiple use of work orders
People changing spare parts specs resulting in downstream failures
I.T data corruption - not a clear understanding of what was
needed
Stores parts issues at machine level and not component level
Cultural issues - quick or bandaid fixes, addressing effects and not
root cause
Many mistakes because we didnt properly understand the software many phone calls to Jason and Stuart
40
16th July, 2002

Mine Crusher Apron Feeder Lube System Upgrade
ER no. ACH580
Recommendations
That the existing lubrication system be replaced with a Woerner lubrication

system. These are very reliable and have the ability to self diagnose faults and
alarm accordingly. There are 3 existing applications at Railton using Woerner
systems no.4 kiln girth gear, no.4 cement mill girth gear and the kiln clinker
cooler grate. The estimated capital cost is $40,150.
That some improved management of the crushing system occurs to try and
prevent the hopper stopping because of being at low level e.g if trucking problems
occur reset the TPH aim to suit the operating conditions.
Benefits
Reduced maintenance costs for the lube system (50% of $1,600) = $ 800 p.a
Reduced hired excavator costs for unblocking (50%of $1,500) = $ 750 p.a
Reduced operations overtime
$23,000 p.a
$24,550 p.a
Total savings
41
Using AvSim to aid capital justification

Reliability information
Mine system
Mine system availability based on YEM99 01 data A= 40.55%

Eliminating 50% of apron feeder failures A=43.1%
Eliminating most failures A=46.3%
Apron feeder
Availability based on YEM01 data A=86.3%
Eliminating 50% of faults A=92.9%
Eliminating most faults A=97.4%
Maintenance savings
Eliminating 50% of faults will realise
Maintenance savings of $ 800 p.a.
Hired excavator savings of $750 p.a.
Operational overtime of $23,000 p.a calculated by
Driving failure mode of the lube system = Changeover valve
failure
MTBF = 594 hours with MTTR = 30 hours
Estimated total operating hours per year = 2,700 hours
Estimated failure per year = 2,700 / 594 = 5 failures
Hours lost per year due to failure = 30 x 5 = 150 hours
6% gain in availability of 2,700 hrs also = 150 hours
50% represents 75 hours lost / year
Cost = 7 operators x 75 hours x $45 /hour = $ 23,000 p.a
42
The end
43

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A practical application of RCM principles at the

Cement Australia Railton plant

Cement supply & distribution

Cement & lime supply

in Tas, Vic & NSW

in Qld & NSW

Sales & marketing roles

Gladstone / Rockhampton Qld(1.7Mt)

Manufacturing in Kandos NSW(0.5Mt)

The Process we went

Step 4 = The actual project

Strategic Industries Research Foundation (Vic) (SIRF) contacted in mid 1998 to

Existing maintenance systems well defined and quite effective

They recommended we adopt a Reliability Centred Maintenance approach

Step 2 = PILOT STUDY - NO 5 CEMENT MILL

Step 2 = PILOT STUDY - site wide planned /

number of work orders

Step 3 - software - AvSim & RCMCost by

Step 3 - software - AvSim & RCMCost by

Step 3 - software - AvSim & RCMCost by

Lifetime costs simulated

Step 3 - software - AvSim & RCMCost by

"Bath tub curve" - Weibull

Wear out failure

Step 4 = The Actual Project

How will we do this ?

We have to align our maintenance strategies for poorly performing

How will we do this ?

We have reasonable, historic work order data

Typical breakdown work order data for a single machine

WORK ORDER DESCRIPTION

MACHINE NO. 1656 = MINE LIM ESTONE FEEDER

CHECK BLOCKED FILTER ALARM IN HYD PUMP - NEW MINE

APRON FEEDER JAMMED

6 F G1BRH 22 10 1998 1 LIMESTONE FEEDER JAMMED CLEARED FEEDER AND

APRON FEEDER JAMMED

6 F G1BRH 22 10 1998 2 ADJUSTED REGULATING VALVE TO CLEAR BLOCKAGE

APRONFEEDER WONT RUN.

6 F G1PGM 20 11 1998 1 ADJUSTED PRESSURE TO MAX. 350BAR BUT COULD

APRONFEEDER WONT RUN.

6 F G1PGM 20 11 1998 2 NOT MOVE FEEDER. ENDED UP DIGGING FEEDER

APRONFEEDER WONT RUN.

6 F G1PGM 20 11 1998 3 OUT WITH EXCAVATOR

APRONFEEDER WONT RUN.

6 E G1MRW 30 11 1998 1 ASSISTED FITTER UN-BLOCKING APRON FEEDER

CHECK LOW TONNAGE OUTPUT FROM LIMESTONE FEEDER

9 1999 1 CHECKED AND ALL OK ELECTRICALLY. SUSPECT FEED

CHECK LOW TONNAGE OUTPUT FROM LIMESTONE FEEDER

9 1999 2 CHUTE BLOCKAGE.

4 2000 1 FOUND THAT LIMESTONE HAD JAMMED APRON FEEDER

3002870 LIMESTONE FEEDER JAMMED.

6 1998 1 CHECKED FILTER LOOKED OK CLEANED OUT ANYWAY

3002870 LIMESTONE FEEDER JAMMED.

4 2000 2 ASKED QUARRY PERSONAL TO REMOVE LIMESTONE

3002870 LIMESTONE FEEDER JAMMED.

3002379 NEW MINE APRON FEEDER ZSS TRIP

4 2000 1 FEEDER JAMMED

3002379 NEW MINE APRON FEEDER ZSS TRIP

4 2000 2 DUG OFF & ALL OK

3003861 1656 APRON FEEDER JAMMED

5 2000 1 OPERATED APRON FEEDER MANUALLY, FEEDER STILL

3003861 1656 APRON FEEDER JAMMED

5 2000 2 JAMMED, HOPPER HAD TO BE DUG OUT.

3003877 1656 LIMESTONE FEEDER JAMMED