EAME Miners Forum Malaga - 2007
Mining expertise, business solutions
Financial Management of Equipment Evaluating Maintenance & Repair Costs
Direct Equipment Costs
Expenditures against equipment as a result of Planned Maintenance, Breakdown or Preventative Maintenance
In-Direct Equipment Costs
Expenditures undertaken to support and facilitate fleet maintenance; on-site & off-site
In-Direct Machine Financial Requirements
On-Site Support
Set Up Costs Tooling Service Vehicles Planning Component Inventory Parts Inventory Losses Consumable Inventory Safety Operation Severity
Off-Site Support
Inventory Management Non Cat Parts Sourcing Continuous Improvement Technical Support Warranty Financial Management Business System Rebuild Logistics
Staffing
Staff Recruitment HR & Payroll Management Tree Logistics Training
Critical Success Factors
Components vs Machines Staff vs Machines Component Planning Early SMU Management Crane Availability Fuel Truck Availability Utilization vs. Maintenance Component Life
On Site Support
Set Up Costs
Mining normally in Remote Location Internet connection
V-SAT Maintenance of communicatiions Computers Laptops Consumable Dispensing Units Lubricant Suction Units Air Lines Demarcation Lines CC & Safety Signage Walk Around PM Stand Kidney Loop Equipment Integration Drip Trays Tooling Cabinets and Tool Boxes Workbenches
On Site IT
Workshop Set Up
PM Bay Set Up
On Site Support
Set up Costs
Oil Dispensing Units
Environmentally complying Cubes Fine in-line filtration Pump Consumables Pressurized Water Supply allowing localized and efficient washing Furniture IT Printers, Scanners etc. Cupboards, cabinets Planning Boards
Wash Bay Facility
Office Facility
On Site Support
Tooling
Tooling provided to all employees?
Finance Costs Specialised Tooling Requirements
Lost / Replacement tooling Tooling Supply Lifting Chain Safety Requirements Non Cat Tooling Sourcing Tooling Supply Depreciation Finance Charge
On Site Support
Service Vehicles
Mobile Fueling Truck
In pit daily servicing Daily Inspection of machines Lubricant and Coolant supply Selection
Mobility Speed Reliability Supply Spare parts & Stocking
Light Vehicles
Fleet Coverage On Board Tooling Requirement Maintenance Parts Supply and Stocking
On Site Support
Service Vehicles
Specialised Support Equipment
Telehandlers
Facility Manoeuvrability Component Replacement Man Basket Function Parts and Component Manoeuvrability General Workshop use Component replacement Heavy / Large item transport
Fork Lift
Hiab Truck
Specialised Maintenance Equipment
Welding Bay
Mobile / Stationary Welding Sets Work benches Mobile / Stationary Air supply in field
Compressor
On Site Support
Planning
Storage of WIP (Backlog) Parts
Shelving Plastic Boxes Clipboards Warehouse space Component Planning Boards PM planning Boards Business Dealer System
Capture planning functions
Planning Visual Aids
Information Storage
Machine History Files Storage Room
On Site Support
Parts & Component Inventory
Parts Availability
Lead Time Variables Fast Moving vs. Slow Moving Stock Effect on Machine Availability
Finance Charges Warehouse Racking and Manoeuvrability
Logistics
Exchange Components
Increase Availability Component Stands Installation Kits Extra Seeded Components Finance Cost Depreciation Rust Prevention Forklift Access
Charges
Component Space Allocation
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On Site Support
Consumable Inventory & Losses
Lubricant
Grease, Oil & Coolant Finance Costs Logistics
Welding Consumables
Nitrogen & Oxygen Bottles Grinding Discs Welding Rods Rags Contamination Control
Wipes Mats
Workshop Consumables
Stationary
Printed Forms Printer paper and cartridges
Theft Dead Stock Wastage
Oil & Fuel
Incorrectly ordered parts Warranty Claims Poor Workmanship
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On Site Support
Safety
Personal Protective Equipment
Vests Boots Glasses Hats Welding Screens Flashing Lights Buggy Whips ROPS Mounting and Dismounting Standards Lock Out Devices Wheel Chocks Chains Periodic Inspection Crane Inspection and Certification Lifting Training
Vehicle Safety Enhancements
Fleet Safety Enhancements
Lifting Device Certification and Training
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On Site Support
Operation Severity
Operation Severity Measurement
Consistency Key Performance Indicators Long Term Abuse
Transmission Shifting Retarder Control Torque Stall
Operator Influence
Pit Floor / Haulroad Influence
Fleet Life Labour Hour Calculations Workshop Space Calculations Tyre Maintenance Strut Maintenance Body Maintenance Tyre Maintenance
Loading Practices influence
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Off Site Support
Inventory Management & Non Cat Parts Sourcing
Central Inventory Control
Initial inventory stocking Min / Max Setting Re-ordering metrics Parts Clearing In country logistics GET Management
Cost / Hour Hrs / Change CTS Inspections Wear rates Shoe Life Link Life Roller Life Frame Life
Fast Moving Parts
Undercarriage Management
Non CAT Sourcing
Mega Water Truck Spares Service Truck Spares Fork Lift Parts
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Off Site Support
C.I., Technical Support & Warranty
Continuous Improvement
Site Audits Conference Calls PIP/PSP Completions Fleet Updates
Technical Support
Repetitive Machine Issues Urgent Welding and fabrication Software and Support Documentation Warranty Follow Up
Warranty
Documentation Processing Caterpillar Follow Up Reporting Claim follow up and resubmission
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Off Site Support
Business System and Financial Management
Parts and Work Order Management
Parts Requests and Additions Work Order Opening Invoicing Requirements Cost Control Work in Progress Backlog Parts Non-moving Parts
Scheduled Reporting
Fleet Costs Management
Expenditure versus Budget Projected Costs High Costing Machine Areas Machine Specific Reports Re-alignment of maintenance practices along with expenditures
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Off Site Support
Rebuild Logistics
Fleet Long Life Component Projections 12 month Planning process
Planned / Unplanned Component Replacement
Pre-Prepared 100% Rebuild Kits
Component delivery to C.R.C. Workshop (Component Tags and Repair Instructions)
Pre-Ordering 100% Kits for all Components (Seafreight)
The 3 week Component Return Cycle
Component Return to M.A.R.C. Site C.R.C. Strip, Rebuild & Test (Following R.P.I. Administration)
Pre-Prepared Labour Enhancements and Structure Upgrade
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Staffing
Recruitment, HR & Payroll
Interviews, medicals and appointments
Selection Criteria Aptitude Testing Medical Letters Unsuccessful Medicals Appointment Letters
Inductions
Company inductions Safety inductions Initial training
Union Negotiations Staff quantity increase
Payroll Stresses Allowance calculations
Provident Funds
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Staffing
Management Structure
Project Manager
Maintenance Supervisor
SHE
Maintenance Planner
Parts Supervisor
Service Bay Supervisor
Welding Supervisor
Electrical Supervisor
Shift Supervisor
Workshop Supervisor
Abraham Sackey Alfred Tawiah Samuel Ayiku Francis Gyakye Alex Baah Kwasi Amande Isaac Nyarko Emmanuel Ewudzi Dominic Cudjoe Asare Baidoo Benjamin Ahorsey Buami Xola GeorgeNkrumah CyrusSampson Larbi Fuel Bay Inspectors Dan Venance Samuel Incoom Paul Bluvi Prince Yeboah Lord Cudjoe Wakson Supervisor Seidu Dawuda Ibrahim Abubakari Francis Kwofie Augustine Tsiwah Joel Ankomal lBen Takyi Kwesi Ano
Daniel Acheampong Lawrencia Ofosu Gyan Martin Satekla Gabriel Cudjoe Hagar Nyamekye Kofi Gyimah Thomas Appiah Lawrence Mensah
Ebenezer Oppong Christian Kumordzi Anthony Aquach George Blay
Samuel Boadi Bramsco Isaac Kyereboah Wilson Vordzorgbe John Opoku Emmanuel Nsiah Adams Gaddiel Amoako Yussif Seidu Alfred Yankson
Isaac Obeng Abdul Karim Nicholas Kuevi Fuseini Amandu Moses Ativo Richard Kofi Norgbey Samuel Danquah Agbessi Bamidele Kingsley Appiah Richard Nyanney James Bilini Samuel Arthur Bekai Darku JohnTanko AyubaBen Vondey Maxwell Boaitey Crane operators Ebenezer Asimeng
Admin Manager
Vehicle Info Manager
Fred Akuffo Emmanuel Amu Charles Mends William Asare Donkor Emmanuel Bart-Plange James Abban (C) James Asamoah (C) Hose Technician Rowland Bessieh
Terrence Blankson Daniel Adjah John Oko Amarteifio Samuel Okine
Lube Truck Edward Kwame Kyi Akakpo Michael Franklin Kwofie Peter Danso William Ampah Patrick Boakye CIL Inspectors George Solomon Richard Mensah John Kyei Bosco
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Staffing
Logistics
Transport
Staff transport to/from work Expatriate travel to/from site for leave/training Leave / Training Flights Visitor travel arrangements External trainers On site accommodation for expatriate staff
Furniture Kitchen Utensils Cleaning and Laundry
Accommodation
Hotels Local accommodation for training Visitor and Management Hotel Costs Local Food supply
Dayshift/Nightshift
Food
Expatriate Meals Visitor / Management Meals
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Staffing
Training
On-Site Training
Room and Projector Training Co-ordinator Updated Schedules Initial induction
Safety Contamination Control
Off-Site Training
Technical Supervision Management Soft Skills Traineeship
On-Line Training
SIS Parts Pro New Product Information
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Critical Success Factors
Components vs. Machines
How many spare components do I need on site?
Fleet Availability Requirements Rebuild Turnaround Time Rebuild Failure Rate Component Durability Fleet SMU Proximity Model Importance Maintenance Strategy
On-Site / Off-Site Repair Reman Strategy
Fleet Example
1 Power Train Exchange per 10 Equipment Models
>90% Availability <1 month turnaround <10% failure rate >80% Rebuild Life
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Critical Success Factors
Staff vs Machines
How many staff do I need on site?
Fleet Size
Qty of PMs per day Average Breakdowns per day Component Changeouts per day Proximity to Component Changeouts Specialised Work Required
Welders (Body repairs)
Fleet Age
Breakdown % per day Quality of work Scope Capabilities Training Needs PM Supervisor Toolstore Backlog Store Maintenance Planner
Workmanship
Key Areas
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Critical Success Factors
Component Life & Planning
Component Life Extention
Increasing component life does not mean decreasing cost per hour Increasing component life and achieving budgeted rebuild cost will decrease cost per hour Rear Axle Life
Kidney Looping Condition Monitoring High efficient filters Continuous Monitoring
Oil Cleanliness
Fleet SMU Proximity Implication
Try to avoid Component Change-Out Peaks Be aware of the possibility of component potential failure increase. Plan 12 months in advance Ensure Parts and Rebuild Centres are aware Reman option Recondition option New option After/ Before Failure option Condition Monitoring option
Replacement Strategy
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Critical Success Factors
Early SMU Management
Early Hour Principles
Be aware of the Honeymoon Period! Utilize Training Opportunity Keep Work Efficiency High Ensure the Asset is looked after, not the breakdown Ensure Systems and Procedures are adhered to.
Contamination Control Safety
Keep discipline consistent Assign Roles and responsibilities Ensure fully furnished workshop
Tooling Fabricated Stands Fabricated Steps
Plan some components early Validate parts kits
PM Component Replacement
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Critical Success Factors
Crane & Fuel Truck
Crane Usage
Vital in machine build Component Changeouts
Dump Bodies
Fuel Truck Availability
Vital for all tracked machines
Fuel Truck Spec
Fuel Capacity Oil Types Pump capacity and flow rate
Quantity of fuel trucks
Tracked Fleet quantity Strategy
Truck fueling In pit Fuel Bay
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Critical Success Factors
Utilization vs Availability
Projected utilization of fleet key to facility and maintenance planning
Components Staff Workshop Space Tooling Rebuild Centres
Utilization is directly proportionate to machine downtime
Availability in relation to calendar hours will vary due to machine utilization Example
8760hrs Calender Hours 50% Utilized 4380 hrs worked 800hrs downtime 91% Availability 75% Utilized 6570 hrs worked 1200hrs downtime 86% Availability
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In-Direct Machine Financial Requirements
On-Site Support
Set Up Costs Tooling Service Vehicles Planning Component Inventory Parts Inventory Losses Consumable Inventory Safety Operation Severity
Off-Site Support
Inventory Management Non Cat Parts Sourcing Continuous Improvement Technical Support Warranty Financial Management Business System Rebuild Logistics
Staffing
Staff Recruitment HR & Payroll Management Tree Logistics Training
Critical Success Factors
Components vs Machines Staff vs Machines Component Planning Early SMU Management Crane Availability Fuel Truck Availability Utilization vs. Maintenance Component Life
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