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Gestin del

Mantenimiento de
Equipo Pesado
Profesor : Augusto Ayesta
Reliability MTBF

Availabilty & Utilization

70
60

MTBF
Ta rget

April

May

June

July

40

5
4
3
2

0
Janu ary
Ma rch
May
July
Sep temb er November
February
April
June
August
October
Decembe r

September
November
August
October
December

Ta rg et
MT TR w/o Del ays

60

20

50

MT TR

80

MTBF (Hours)

80

40
January
March
February

Mean Time to Repair MTTR

1 00
Availability
Utilization
Target

90

M TTR (hours)

100

1
Janu ary
March
May
July
Septe mb er Novemb er
February
April
Jun e
Au gust
Octob er
De ce mb er

Maintenance Ratio MR
0 .6

MR
Target

0 .4
0 .3

Reliability MTBF

Availabilty & Utilization


100

70
60

May
April

J uly
June

40

Maintenance Ratio MR
0 .6

5
4
3
2

0
January
March
February
April

September
Nov ember
August
October
December

MTTR
Target
MTTR w/o Delay s

60

20

50
40
January
March
F ebruary

MTBF
Target

80

Target

May

June

July

September
November
August
October
December

1
January
March
February
April

May

June

July

September
Nov ember
August
October
December

100

MR
Target

0 .5
0 .4
0 .3
0 .2
0 .1
0
Janu ary
March
Fe bru ary
Ap ri l

May

Jul y
Jun e

Septemb er
No vemb er
Augu st
Octob er
December

Disponibilidad %

June

Sep te mb er
Novemb er
August
October
De cemb er

MTBF (Hours)

Apri l

Jul y

Mean Time to Repair MTTR

100
Utilization

80

Ma y

0
Ja nua ry
March
Feb ru ary

Av ailability

90

0 .1

MTTR (h ours)

0 .2

La bor/Op. hours

Labor/Op. hours

0 .5

90

80

70

60

25

45

65

85

105

125

142

162

182

La diferencia........

Mina
Disponibilidad

A:

B:

C:

D:

92

92

88

95

Proyecto

Exploracin

Desarrollo

Produccion
Mina >>>
Planta

Activos
>>>

Activos

Comercializacin

Cierre

Objetivos

ROI , VAN ,Desarrollo Sostenible

Gerencia Estratgica de Activos


Productividad
Utilizacin
Costo

= P x U / C

Historia de la Gestin del Mantenimiento

Programar
&
Reparar

Repara
Adan & Eva

Monitorear,
Predecir,
Programar,
& Reparar

WW II

1980s

Gerencia Estratgica de Equipos (SAM)

Evolucin
Tipo de Gestin vs Confiabilidad

Gerencia Estratgica de Activos

Gerencia Lider
Planeamiento Estratgico
Sistema Integrado de Informacin

Gerencia de Equipo (Activo)


Planeamiento de Equipos(SELECCION)
Produccin(APLICACION)
Mantenimiento(SISTEMA,INDICADORES,REPORTES)
Logstica(RECURSOS)

Gerencia de la Persona
Responsabilidad , Autoridad
Desarrollo y Reconocimiento

Sistema de Mantenimiento

Mantener los activos al nivel de


rendimiento requerido en su contexto
operacional con equilibrio entre
confiabilidad e inversin

Funciones conocidas y de xito


probado

Organizacin

Indicadores de Gestion

Definicin clara y precisa

Necesarios para Administrar

Entendidos por toda la Organizacin

Enfoque de oportunidad de Mejora

Proceso de Mejora Continua

Reportes Gerenciales

Elemento para toma de decisiones

Muestran
control de la situacin
efectividad de la gestin
eficiencia de uso de recursos
ruta para mejora de indicadores
soluciones

Temas :

Aplicacin

Sistema de Mantenimiento

Indicadores de Gestin del


Mantenimiento

Reportes

Gerencia Estratgica de Activos

Gerencia Lider
Planeamiento Estratgico
Sistema Integrado de Informacin

Gerencia de Equipo (Activo)


Planeamiento de Equipos(SELECCION)
Produccin(APLICACION)
Mantenimiento(SISTEMA,INDICADORES,REPORTES)
Logstica(RECURSOS)

Gerencia de la Persona
Responsabilidad , Autoridad
Desarrollo y Reconocimiento

EMS
Gestin de la Aplicacin
Deje a la Aplicacin guiar su
Estrategia de Mantenimiento

Trabajar Juntos hacia


METAS COMUNES ...
El mejor diseo para la Aplicacion
Equipo operando en Aplicacin
controlada y predecible
Mantenimiento Proactivo
adaptable a los cambios en Aplicacion

Como se trabaja para obtener los mejores resultados ?

Produccin
Actual versus Target Ton/day
200

Tons/day.Target
Tons/day.Actual
Ore. Actual

Tons
Thousands

150

Ore. Target

100

50

0
January

February

Analysis

March

April

May

June

July

August

September

October

November

December

Implementacion de La Gestion de la Aplicacion


Definir las Condiciones de Operacin Claves ...
(identificar parmetros crticos y frecuencia de anlisis).
Usar fuentes de monitoreo existentes
Reporte resultados periodicamente... Use tendencias
Reacione de acuerdo a la situacin.
Evaluacin ms avanzada y profunda
Modifique su Operacin - Aplicacin
Modifique su Estrategia de Mantenimiento.

Definiciondel Camino
de Acarreo
Area de Carga
Dump
Camino Principal

La Severidad de la Aplicacin depende:


Ahora..van a pensar
que soy el
culpable.. !!

Veloc.
Suelo:
-RR
-% Pendiente

GVW=EVW +
Payload*

Rimpull ,Curvas de Traccin Velocidad

Curvas de Capacidad de
Frenado (Retarding) El
principio.........

Use sus Recursos para monitorear

Observacin en campo
Sistemas en la Cabina,
data del VIMS
Nueva tecnologa (CAES)
Sistema Dispatch
Reportes de Produccion
others.

Recoleccin de Datos
Parametros del equipo *

Modo de
Operacion

RPM de Motor

Consumo Comb.

Aplicacin Frenos

Temperaturas Freno

Trasmision Shifts

Viaje
Parada
Carga
Descarga

Solo Vims

(4) Presion en Cilindros de


Suspension

Rack de Maquina
Pitch de Maquina
Load Bias

Fuente de datos
TPMS o VIMS

Etapa de Carga
Del.Derecho
16000

STRUT PRESSURES (kPa)

14000
12000
10000
8000
6000
4000
2000

Del.Izquierdo

Post.Izquierd

Post.Derecho

Acarreo Cargado ...


RIGHT REAR

LEFT REAR

20000

Giros

18000

Strut Pressures (kPa)

16000

14000

12000

10000

8000

6000

4000

2000

0
0

27

99

175

243

310

380

456

530

589

657

733

809

885

945

998

1056

1094

Distancia del Camino Acarreo (m)

1105

1127

1182

1258

1306

1314

1327

20,000
18,000
16,000
14,000
12,000

Management Line

10,000
COMPOSITE STRUT PRESSURES (kPa)

8,000
6,000
4,000
2,000
0
-2,000
-4,000
-6,000
-8,000

Management Line

-10,000
-12,000
-14,000
-16,000
-18,000
-20,000
37

107

186

248

325

426

540

685

802

884

946

1021

1091

1143

1183

1223

1268

1334

1420

1496

1576

1613

1629

1635

DISTANCE ALONG HAUL ROAD (meters)

20,000
18,000
16,000
14,000
12,000

Management Line

COMPOSITE STRUT PRESSURES (kPa)

10,000
8,000
6,000
4,000
2,000
0
-2,000
-4,000
-6,000
-8,000

Management Line

-10,000
-12,000
-14,000
-16,000
-18,000
-20,000
1

93

201

319

432

552

660

768

876

986

1096

1206

1315

1423

1532

DISTANCE ALONG HAUL ROAD (meters)

1640

1749

1832

1934

2043

2177

2369

2531

2571

2605

20

18

2.5

16

30
Cycle

1.5

Loaded
Empty

14
12
10

25

% of Overload

km/hr

Cycles per hour

% of Overload

Average Speeds

Cycles per Hour


3.5

0.5

20

15

10

6
0
January
March
May
July
September November
February
April
June
August
October December

5
January
March
May
July
September November
February
April
June
August
October December

January
March
May
July
SeptemberNovember
February
April
June
August
October December

Power Train Shift Counter


Average Payload

Fuel Consumption
240

230

Load (Tons)

180

160

140

220

210

200

140

Number of LU Eng.

200

Lts/hr

Lock Up Clutch Engagement per Cycle

120
100
80
60
40
20

120
January
March
May
July
September November
February
April
June
August
October December

190
January
March
May
July
September November
February
April
June
August
October December

Situation Analysis

OPERATION CONDITIONS

January
March
May
July SeptemberNovember
February
April
June
August October December

Budget vs Actual Maintenance Cost


500

3.5
3

400
12

US$
Thousands

USc/Ton-km

14

10

2.5

300

200

1.5
1

100

0.5

0
December

January

8.99

February

9.23

March

9.29

April

9.41

May

9.29

June

9.76

July

9.88

August

10.59

September

10.53

October

10.59

November

10.65

December

10.77

Budget

January

February

March

April

May

June

July

August

September

October

November

December
379,681

136,373

154,116

170,802

249,504

258,704

250,240

307,728

304,630

314,872

402,781

362,404

Actual

109,098

130,999

145,182

249,504

245,769

225,216

292,342

298,538

314,872

422,920

398,644

474,602

Budget

136,373

290,489

461,291

710,795

969,499

1,219,739

1,527,467

1,832,097

2,146,969

2,549,750

2,912,154

3,291,835

Actual

109,098

240,097

385,278

634,782

880,551

1,105,767

1,398,109

1,696,647

2,011,518

2,434,438

2,833,083

3,307,685

Prog. Hr..

160,704
163,296
Programmed

180,792
183,600
200,880
194,400
200,880
Hours
showed
for reference
purposes

241,056

233,280

301,320

291,600

301,320

Op. Hr.

136,373
154,116
194,028purposes
187,680
Operating
Hours170,802
showed187,128
for reference

228,473

219,678

281,010

252,840

264,894

Major Actions

Major Drivers

COST REPORT

230,796

M illions

Operating Cost

EMS
Gestin del Sistema de
Mantenimiento por
Indicadores
Benchmarking Medidas de Rendimiento....
...Kpi (Key Performance indicators)

La diferencia........

Mina
Disponibilidad

A:

B:

C:

D:

92

92

88

95

Funciones de la Gerencia de Mantenimiento


Prevencin de Consecuencias de las Fallas Mantener al
equipo en excelentes condiciones operativas por periodos de
tiempo extensos e ininterrumpidosmaximizarUTILIZACION y
MTBS =CONFIABILIDAD
Accin correctiva inmediata :Mantener un grupo de
personas ,facilidades,herramientas, tcnicas, comunicaciones y
sistemas con el objetivo de retornar rpidamente al equipo a
produccin despus de una paralizacin programada o no
programada : MINIMIZAR Paralizaciones (demoras)
/Optimizar MTTR
Uso eficiente de recursos Administrar activos y gastos para
lograr objetivo de produccion con un EQUILIBRIO entre
confiabilidad y costo"
Optimizar la vida econmica de los activos"Planificar y
optimizar la vida del equipo en un proceso de mejora continua
:APLICAR el RCM/PMO SAM

Sistema de Mantenimiento de Equipo


PRODUCCION

Maquina
Trabaja
Inspeccion
Diaria Op.

Produccion
Horas Op.

MANTENIMIENTO (E)
Mant.Diario Campo

PLANEAMIENTO (P)
Backlog Programa

Inspeccion
Checklist
ResultadoNo Critico
No Necesita
Criticol

Orden T.
Inspect

Update
Programa
Manten.

PM,
Inspeccion,
Repar
Repar

Parar

Reunin (S)
Prod/Mant

REPUESTOS (S)
Dispon.
Entrega

Orden T

Maquina
Identificacipn
Analisis Plan

Reportes
Disponibilidad
Produccion

Data Dia

Analizar
Data
Programado
No Programado
Reportes

RCM/PMO ANALISIS (A)

Fail
Actualizar Historia
Historia

MANTENIMIENTO(E)
Taller
Control
Calidad

La experiencia ha mostrado la necesidad de ciertas


funciones en todo Sistema de Administracin del
Mantenimiento
Mantenimiento Preventivo (E)
Monitoreo de Condiciones (P)
Administracin de backlogs (P)
Administracin de Componentes (P)
Administracin de Repuestos (S)
Taller de Mantenimiento,Campo,Taller Reparacion (E)
Sistema de Informacin / CMMS ERP (A)
Anlisis de Rendimiento del Sistema,Kpi (P)
Administracin de Problemas o Analisis RCM (A)

Benchmarks Para Minera...


operaciones.. Administracion de cargas, demoras,
tiempos de carga, tiempo de exchange , produccion,
costo por tonelada, etc..

aplicacion ... pendiente/ variacion, resistencia


a la rodadura, mantenimiento de caminos de acarreo,
trafico, etc..
mantenimiento disponibilidad, utilizacin etc..

MINING
METRICS
1

CALCULATION

- Components Control

Availability

A=

Utilization

U=

MTBF

Operation Hours

Operation Hours

MTBF =

MR=

SW=

Operation Hours
Ns. of Failures or Shutdowns

Repair Hours

MTTR=

MR

% SCHEDULED WORK

x 100 (%)

Programmed Hours

Ns. of Failures or Shutdowns

Mean Time to Repair

Maintenence Ratio

x 100 (%)

Operation Hours + Maint. Hours

Mean Time Between Failure

Operation Hours
Ns. of scheduled repairs
Ns. of Failures or Shutdowns

x 100 (%)

10

SERVICE ACCURACY

Maintenance Hours Control

Operation Hours Control


Operation Hours Control
Shutdowns counter

Repair Hours Control


Shutdowns counter

Shutdowns counter with Scheduled/


unscheduled identification
Shutdowns Record identifying :
Component/Sympton/Times:Repair/Waiting/
Parts & materials used/ Labor/ Cause if its
known.
Analysis priorities:
- Costs / Availability / Reliability /
Labor

List of Top Ten Problems

SHUTDOWNS PER
SYST. / COMPONENTS

Operation Hours Control

Maintenance Man-Hours Control


Operation Hours Control

Maintenance Man-Hours

TOP TEN PROBLEMS

World Class Mines


Benchmarks

WHAT CAN I OBTAIN WITH

- SMU

Records : - Service History

(Hours/SMU/Work Done)

MTTR

MA NAGEMENT

WHAT IS NEEDED TO

Machine History

EQUIPMENT

SA=

SHP - SHE
SHP

x 100 (%)

PM / Services Program (Hours)


PM / Services Executed (Hours)

SHP: Service Hours Programmed


SHE: Service Hours Executed

Age of Equipment

YES

(& kind of Life)

Mine operation requirements


satisfaction level

92 % nuevos
88 % viejos

Equipment Use.
Labor/Parts, Burden estimation

90 %

A=

MTBF
MTBF + MTTR

Turnaround
(Effectiveness &
Response of Repairs)
Effort invested
Quality of repairs/labor

x 100 (%)

3 - 6 hrs
0.2 new
0.3 old

Who is in control !
The Maintenance Organization or
the Machine

80 %

PAIN Location & Severity .

YES

Correct response to failures:


- Parts Inventory
- Mechanics Training
- Improve inspection Programs
- Operators/Pit Supervisors training
- ...
Fundamental information for the
PROBLEM MANAGEMENT TEAM
(Customer / Dealer / Factory)
Planning / Scheduling Efficiency
Repair Centers following planned activities ?
General planning accomplishment
Are I'm standing on a solid base ?

Backlogs age
Quantity
Estimated hours to perform
Backlogs

80 hrs new
60 hrs old

Reliability

11

BACKLOGS
CONTROL

12

RECORD KEEPING

Forms designed to capture the necessary


Information / Computarized System
Organization personnel commitment

Information Source of the Maintenance


Operation

13

TRENDS

Consummables control
S.O.S. - Results Interpretation
Tests / VIMS Results . . .

Prognostics
Component Life Management
Problem Management

YES

Within 10 %

YES

100 %

YES

Porqu MTBS?
comprarse >>> mano obra en
exceso,facilidades , repuestos, etc. = bajo MTTR.
La disponibilidad puede
MTBS

debe ganarse >>> Sistema administracin


de equipo eficiente, i.e. mantenimiento, inspecciones,
backlog, planeamiento/ programacin, repuestos,herram.etc
Alto MTBS

= Confiabilidad = eficiente uso de recursos

Reliability CONFIABILIDAD

R=e

-T/MTBF

Donde T = intervalo de tiempo


MTBF :tiempo medio entre fallas
MTBS tiempo medio entre paralizaciones (Programadasy No)
MTBS= Horas de Operacion/# de Paralizaciones
MTTR=Horas de Paralizacion/# de Paralizaciones
% Disp.Mecanica=MTBS/MTBS+MTTR

Efectividad del Mantenimiento


Programa de Mantenimiento
Mantenimiento Preventivo
Inspecciones & Monitoreo
Planeamiento & Programacin
Reparacin antes de falla

MTBS

Edad
Diseo

Mas Complejo

Aplicacin
& Operacin

Mas Severa

Effect of MTTR on Availability


100
95

Availability - (%)

90

MTBS
80
60
40
20

85
80
75
70
65
60
55
50
45
40

9 10 11 12 13 14 15 16 17 18 19 20

MTTR - (hours)

Effect of MTBS on Availability for various MTTR


100

Availability - (% )

95

MTTR

2 hrs
3 hrs
4 hrs
5 hrs
6 hrs
7 hrs
8 hrs
9 hrs

90
85
80
75
70
65
60
5

15

25

35

45

55

65

75

85

95 105 115 125 135 145 155 165 175 185 195

MTBS - (hours)

MTBS vs. MTTR for various Availabilities


20

Availability %

85%
86%
87%

MTTR - (hours)

15

88%
89%
target operating range

90%

10

91%
92%
93%

94%

MTTR
3 - 6 hrs

95%

MTBS
60 - 80 hrs

10

20

30

40

50

60

MTBS - (hours)

70

80

90

100

Ranking de Paralizaciones codificado


Flota OHT Jan-June 2001
Codigo
5000
4209
1429
9600
4250
7300
1000
7319
9100
9500
4200
1350
7200

Descripcin
Hydraulic System
Tires & Rims
Lights
Wait on Mechanic
Wheel Brake System
Oper. Compartment
Engine
Mirrors
Aux. Equipment
PM
Wheel System
Cooling System
Suspension

Horas
Horas Operacin= 14769
Paralizacin # Paralizac. MTTR MTBS
824.44
130
6.34
114
298.58
92
3.25
161
70.26
67
1.05
220
78.61
48
1.64
308
328.28
46
7.14
321
75.75
43
1.76
343
248.68
41
6.07
360
15.04
37
0.41
399
43.51
36
1.21
410
1553.88
32
48.56
462
595.34
32
18.60
462
262.49
29
9.05
509
39.83
29
1.37
509

Reliability (MTBS)

Availabilty & Utilization

M TB S (hours)

80

80
70
60

60

40

20

50
40
January
March
May
July
SeptemberNovember
February
April
June
August
October December

6
5
4
3

1
January March
May
July September
November
February April
June
August OctoberDecember

Major Drivers

0.6
MR

Labor/O p. hours

0.5

Target

0.4
0.3
0.2

Major Actions
0.1
0
January
March
May
July
September November
February
April
June
August
October December

GENERAL PERFORMANCE METRICS

Target
MTTR w/o Delays

0
January March
May
July September
November
February April
June
August October December

Maintenance Ratio MR

MTTR

Target

M TTR (hours)

Utilization
Target

MTBS

Availability

90

Mean Time to Repair MTTR

100

100

MR

Proposed Relationship Between MR and MTBS


0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0

20

40

MTBS - (hours)

60

80

Service Accuracy

Service Accuracy

450

100

Service Accuracy

Intervals (hours)

Upper Limit

350

Services

300
250
200

% Services within Range

Lower Limit
400

Target

80

60

40

20

150
100

01/03/96

0
January
March
May
July
September November
February
April
June
August
October December

03/18/96
05/18/96
07/27/96
10/24/96
02/09/96
04/18/96
06/30/96
09/07/96

Services Performed

Major Drivers

% Scheduled Shutdowns
100

% Scheduled Shutdowns

% Scheduled
Target
80

60

40

20
January
March
May
July
September November
February
April
June
August
October December

PLANNED WORK LEVEL

Major Actions

Mina x : Rendimiento de OHT


PM Target Interval
(hours)

Actual Interval
(hours)

Variation
(%)

Impact

250

410.7

+64.3

Engine oil &


filters

500

816.5

+63.3

Front wheel oil

1000

1593.9

+59.4

Transmission
oil & filters

2000

3074.0

+53.7

Steering oil &


filters

4000

6045.0

+51.1

Final drive &


differential oil

COMPONENTS REPLACEMENT PROGRAM

ecember
January
Engines
1st Priority
T.Converters
1st Priority
Transmissions
1st Priority
Differentials
1st Priority
Final Drives
1st Priority

sn3
sn4

February

March

April

May

June

July

August

SeptemberOctober November December


0
0
0
0

Eng 7
TC8
xmsn 7
Diff 8
6
FD11/FD12

Man Hours
Downtime

760
380

72
36

0
0

32
16

376
188

144
72

216
108

224
112

0
0

96
48

0
0

112
56

Availability influence (%) *


Availability influence (%) **

3.78
4.30

0.40
0.45

0.00
0.00

0.16
0.19

1.87
2.13

0.74
0.84

1.08
1.22

1.12
1.27

0.00
0.00

0.48
0.54

0.00
0.00

0.56
0.63

Backlogs estimated hrs


Man Hours
Added Downtime

116
151
29

58
75
0

Availability influence (%) *


Availability influence (%) **

0.29
0.33

0.00
0.00

Note:

* Influence on Target Availability


** Influence on last Month condition Availability

90.00 %
79.12 %

Situation Analysis

COMPONENT REPLACEMENT PROGRAM

Transmissions

Differentials

Hours
Thousands
0

10

Hours
Thousands
15

xmsn1

Diff1

xmsn2

Diff2

xmsn3

Diff3

xmsn4

Diff4

xmsn5

Diff5

xmsn6

Diff6

xmsn7

Diff7

xmsn8

Diff8

xmsn9

Diff9

xmsn10

Diff10

xmsn11

Diff11

xmsn12

Diff12

xmsn13

Diff13

xmsn14

Diff14

xmsn15

Diff15

Target

COMPONENTS ACCUMULATED HOURS

10

Target

15

PROBLEMS. DISTRIBUTION PER SYSTEMS


Cost per System
Cost per System

December 199x (Last Month)

Last 6 Months
35

20.0%

Engine
XMSN/TC
Diff/Finals
Electrical
Frame
Hydraulic
Tires
PMs
Others

30

3.0%
8.0%
4.0%
5.0%
13.0%

Engine
XMSN/TC
Dif/Finals
Electrical
Frame
Hydraulic
Tires
PMs
Others

25
20
15
10
5

31.0%

July

August

September

October

November

December

Systems Influence on Availability

Downtime per System

Last 6 Months

December 199x (Last Month)

17.0%
10.0%

7.0%
6.0%
2.0%
4.0%

23.0%

17.0%
14.0%

Engine
XMSN/TC
Dif/Finals
Electrical
Frame
Hydraulic
Tires
PMs
Others

% of influence per System

60

100

50

Engine
XMSN/TC

80

40
60
30
40

20

20

10

Availability (%)

7.0%

% of Total Cost

9.0%

Diff/Finals
Electrical
Frame
Hydraulic
Tires
PMs
Others

July

COST & AVAILABILITY INFLUENCE

August

September October
Months

November December

Availabilty
Goal

PROBLEMS. DISTRIBUTION PER SYSTEMS


Shutdowns per System

Influence on Reliability (MTBS)

Influence on Reliability

Last 6 Months

7.0%
5.0%
9.0%

4.0%
4.0%
8.0%
25.0%

Engine
XMSN/TC
Dif/Finals
Electrical
Frame
Hydraulic
Tires
PMs
Others

40

25
30
20
15

20

10
10

Engine

Overall MTBS (hours)

27.0%

% of influence per System

30

Diff/Finals
Electrical
Frame
Hydraulic
Tires
PMs
Others

11.0%
0

XMSN/TC

July

August

September

October

November

December

MTBF Trend

December 199x (last month)

Shutdowns per Systems

Influence on Turnaround (MTTR)

Influence on Turnaround

Last 6 Months

7.0%
8.0%

12.0%

10.0%

1.0%
28.0%

17.0%

Engine
XMSN/TC
Dif/Finals
Electrical
Frame
Hydraulic
Tires
PMs
Others

7
6

30

5
4

20
3
2

10

Engine

Overall M TTR (hours)

7.0%

% of influence per System

40

XMSN/TC
Diff/Finals
Electrical
Frame
Hydraulic
Tires
PMs
Others
MTTR Trend

10.0%

July

August

September

October

November

December 199x (last month)

RELIABILITY (MTBS) & TURNAROUND (MTTR) INFLUENCE

December

14

14

12

12

10

10

Parts
Components

Facilities

8.1%

13.5%

Labor

21.6%

Tools

Aux. Eq.

27.0%

8.1%

Delay Hours

December 199x (last Month)

21.6%

Field Service Response Time

July

August

September
October
Months

November

December

Influence on Availability (%)

Delay Causes

Delays Downtime

Tools
Facilities
Parts
Components
Labor
Aux. Equip.
Infl. on Availability

Response Time (min)

20

15

Situation Analysis

10

0
January
March
February
April

May

July
June

September November
August
October
December

MTTR. Field vs Total


7

Field MTTR

Total MTTR

Hours

5
4
3
2
1
0
January
March
February
April

May

July
June

September November
August
October
December

DELAYS & RESPONSE

Backlogs Quantity

Blogs > 30 Days (% of Total)

Estimated Time to Repair

240 Ton Truck Fleet

240 Ton Truck Fleet

240 Ton Truck Fleet

400
Quantity

100

1000

Quantity of BL

200

100

90
800

80

Percentage %

Downtime (hrs)

Executed
300

600

400

70
60
50

200

40
0

April

June
May

August
July

Octuber
September

December
Noviember

April

June
May

July

August
October
December
September
November

Backlog Status

30

April

June
May

August
July

October
September

December
November

Backlogs per System

240 Ton Truck Fleet


100

0.590.77

80

3.24
1.47

Percentage %

2.4

2.44

0.93

60

40

1.35

3.04
20

1.03

April

June
May

August
July

October
September

December
November

4.11

0.65

3.04

Engine
Electrical
Transmission
Hydraulics
Steering
Air Sys.
PM
Tires
Differential
Final Drives
Brakes
Suspensions
F.Wheels
Fire Sup.
Accidents
Air/Cond

Situation Analysis
- The Benchmarks or Targets for Quantity, ETTR will be established. It is noticeable the increase of Backlogs and estimated time to repair them (ETTR).
This is very dangerous; we have to improve our reaction (clean BL List). The Nbr. of BL executed is low and constant. The quantity of Backlogs waiting for
being process is affected by the location of the warehouse. The BL waiting for parts are affecting directly on the age of them, BL (>30)
Corrective Actions
- Considering the amount of BL "ready to go" (Green) we will start scheduling more BL within the planned activities and instructing the supervisors to
increase the use of the window of opportunities of the unscheduled repairs.
- We are working in the relocation of the warehouse.
- We will increase the scheduling of BL and the shop will be instructed to executed 100 % of the planned jobs.

PM Effectiveness

Backlogs executed during PM

70

20

Overall MTBF
MTBF after PM

50

MTBF Target

40
30
20

Quantity per Truck

MTBF (Hours)

60

15

10

10
0
January
March
May
July
SeptemberNovember
February
April
June
August
October December

0
January
March
May
July
September November
February
April
June
August
October December

PM Efficiency
14
12

Hours

10

PM250
PM500
PM1000
PM2000

8
6
4

Target

2
0
January
March
May
July
September November
February
April
June
August
October December

PM EXECUTION

Situation Analysis

12.) Sistema de Registros :CMMS


SISTEMA INTEGRADO DE
INFORMACION ERP
Benchmark:
100% de todas las actividades de mantenimiento y reparacin
estn documentadas por ordenes de trabajo OT /WO
los formatos estn diseados para registrar la informacin
necesaria
informacin y registros de calidad son los fundamentos
para una efectiva Administracin de Equipos ,
fallas = fallas del equipo y del proceso administrativo
la meta es PREVENCION via INTERVENCION.
Recolecione diarimente y registre adecuadamente .

Analisis - Segmentacion
Complejidad de Maquina = Complejidad de Sistemas & Data...
Codigo de Componentes
A ll D a t a
C o m p le x
E n g in e S y s t e m
A ir
I n d u c t io n

F u el S ys.

L u b e S ys.

S t a r t in g

D r iv e t r a in

C h a s s is

C o o lin g - E n g in e

H y d r a u lic s

T ir e s & R im s

G ET

E tc ...

+ .. Repuestos, Mano de obra, T Paralizacin,# Paralizaciones...


Segmentacion:
Sintoma
Repuestos

Trabajador
Turno

Flota
Aplicacion

Ranking de Paralizaciones codificado


Flota OHT Jan-June 2001
Codigo
5000
4209
1429
9600
4250
7300
1000
7319
9100
9500
4200
1350
7200

Descripcin
Hydraulic System
Tires & Rims
Lights
Wait on Mechanic
Wheel Brake System
Oper. Compartment
Engine
Mirrors
Aux. Equipment
PM
Wheel System
Cooling System
Suspension

Horas
Horas Operacin= 14769
Paralizacin # Paralizac. MTTR MTBS
824.44
130
6.34
114
298.58
92
3.25
161
70.26
67
1.05
220
78.61
48
1.64
308
328.28
46
7.14
321
75.75
43
1.76
343
248.68
41
6.07
360
15.04
37
0.41
399
43.51
36
1.21
410
1553.88
32
48.56
462
595.34
32
18.60
462
262.49
29
9.05
509
39.83
29
1.37
509

Sistemas de Informacion Integrados

Process Scope
Historical Focus:
The Machine

Growing Emphasis: The Mine Site


Power
Size
Availability

Process Control:
Lowest Total Mining Cost
Blast

Load
Haul

Drill
Exploration
Plan

Engineering

Process
Control
Execute

Operation

Processing
Plant

Improve

Management
Maintenance

New Technology:
Enabling Process Control in Mining
Global Positioning System (GPS)
Wireless Mobile Communications
On-Board Computing/Sensing
Off-Board Information Management

Global Positioning System

24 Satellites in orbit
20,000 kilometers in altitude
United States $13 billion Department of Defense investment
US government maintains and operates system

Wireless Mobile Communications


Mining and Construction are unique
applications
Require radios with high bandwidth
- Data carrying capability of the network

- For high accuracy GPS positions

Ruggedness to survive

On-Board Computing

VIMSwireless

Payloads and Events

Features

- Allows wireless transmission of payloads and events in near real time


- Utilizes existing CAES radio system
- Reports can be easily tailored using industry standard software

METSmanager

Diagnostics
& Production

Customer Network

Production
Data Payloads

Machine
Events

MineStar
Objectives

Increase mining efficiency by providing


the mining industry with Information
Technology Tools to allow process
change

Integrate the earthmoving machines in


the field with the business applications in
the office including planning, production,
maintenance and financials

MineStar
Trimble & GPS

VIMS Equipped

Caterpillar

CAT/Trimble
Radio
Network

Factory

CAES Equipped

Non-Cat Machines

Mine Office
Dealer
Caterpillar/Mincom
Machine & Material Tracking

Aquila Drill Systems

Truck Assignment
Truck/Loading Tool Payload
Management
Machine Health
Machine Productivity

Machine Location

Machine Health

Material Tracking

Machine Production

Machine Assignment

Drill Management

Fuel Consumption

Torque Stall RPM

Engine Eng7

Engine Eng7
1800

200
180

440
420

160

cu feet/hr

1750

RP M

Lts/hr

Blow By
Engine Eng7

1700

140

380
360
340

1650

120

400

320
3000

5000

7000 9000
Hours

11000 13000

1600

1000

5000

7000
9000
Hours

Oil Consumption

Oil Pressure

Engine Eng7

Engine Eng7

0.2

500

0.15

450

0.1
0.05
0

3000

3000

5000

7000
9000
Hours

Component Hours: 14500

11000

13000

3000

5000

7000
9000
Hours

11000

13000

11000

13000

Engine Eng7
50
40

400

300

1000

SOS Results

350

1000

300

11000 13000

ppm of xx

1000

kPa

Lts/hr

100

30
20
10

1000

Component ID: Eng7

3000

5000

7000
9000
Hours

11000

Installed on: Eq.#7

Evaluation Results

Recommendation

COMPONENT CONDITION MONITORING

13000

1000

3000

5000

7000

9000

Hours
PCR date: January 199x

MTBF
Fleet No. xx
80

Monthly MTBF

M TBF (Hours)

70

Roll. 12 MTBF

60
50
40
30

Fleet Information

20
10

1993

1994

1995

1996

Manufacturer
Truck Model
Acquisition Year
Number of Trucks

1997

Maintenance Cost/hr
Fleet No. xx
35

Monthly Cost

Cost US$/hr

30

Rolling 12

25
20
15
10
5
0

1993

1994

1995

FLEET AGE ANALYSIS

1996

1997

Situation Analysis

:
:
:
:

XYZ
AAA
1993
8

La diferencia........

Mina

Disponibilidad

92

92

88

95

MTBS

70

23

80

20

MTTR

La diferencia........
Evale la Gestin de la Superintendencia de Mantenimiento de dos Minas A y B
Mina A
Enero
Disponibilidad Mecanica
MTBS
MTTR
Precision de Servicio
% programados
MTBS despues de PM
Relacin de Mantenimiento
% Servicio almacn de repuestos
Backlog ejecutados por PM

88.24%
30
4
70
60
40
0.2
80
5

Diciembre
93.02%
80
6
90
70
90
0.6
95
6

Mina B
Enero
86.96%
20
3
70
60
30
0.2
80
3

Diciembre
93.10%
27
2
50
50
20
0.2
90
3

Nomenclatura para interpretacin de


Kpi en:
Operaciones y
Mantenimiento
Reliability MTBF

Availabilty & Utilization

70
60

MTBF

MT TR

Ta rget

MT TR w/o Del ays

60

40

20

50

April

May

June

July

5
4
3
2

0
Janu ary
Ma rch
May
July
Sep temb er November
February
April
June
August
October
Decembe r

September
November
August
October
December

Ta rg et

80

MTBF (Hours)

80

40
January
March
February

Mean Time to Repair MTTR

1 00
Availability
Utilization
Target

90

M TTR (hours)

100

1
Janu ary
March
May
July
Septe mb er Novemb er
February
April
Jun e
Au gust
Octob er
De ce mb er

Maintenance Ratio MR
0 .6

MR
Target

0 .4
0 .3

Reliability MTBF

Availabilty & Utilization


100

70
60

May
April

J uly
June

40

Maintenance Ratio MR
0 .6

5
4
3
2

0
January
March
February
April

September
Nov ember
August
October
December

MTTR
Target
MTTR w/o Delay s

60

20

50
40
January
March
F ebruary

MTBF
Target

80

Target

May

June

July

September
November
August
October
December

1
January
March
February
April

May

June

July

September
Nov ember
August
October
December

100

MR
Target

0 .5
0 .4
0 .3
0 .2
0 .1
0
Janu ary
March
Fe bru ary
Ap ri l

May

Jul y
Jun e

Septemb er
No vemb er
Augu st
Octob er
December

Disponibilidad %

June

Sep te mb er
Novemb er
August
October
De cemb er

MTBF (Hours)

Apri l

Jul y

Mean Time to Repair MTTR

100
Utilization

80

Ma y

0
Ja nua ry
March
Feb ru ary

Av ailability

90

0 .1

MTTR (h ours)

0 .2

La bor/Op. hours

Labor/Op. hours

0 .5

90

80

70

60

25

45

65

85

105

125

142

162

182