Maintenance & Repair Costs - Jones
Content
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
2
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
3
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
– – – – –
4
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
– – – –
5
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
6
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
7
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
• •
8
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
9
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
– –
10
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
11
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
– – –
12
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
– – –
13
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
14
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
15
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
16
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
17
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
18
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
19
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
20
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
21
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
22
Critical Success Factors
Staff vs Machines
• How many staff do I need on site?
– Fleet Size
• • • Qty of PM’s 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
• • • •
23
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
– – – – –
24
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
25
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
26
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 Î 4380 hrs worked 800hrs downtime Î 91% Availability 75% Utilized Î 6570 hrs worked 1200hrs downtime Î 86% Availability
27
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
28
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
2
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
3
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
– – – – –
4
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
– – – –
5
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
6
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
7
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
• •
8
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
9
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
– –
10
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
11
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
– – –
12
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
– – –
13
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
14
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
15
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
16
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
17
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
18
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
19
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
20
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
21
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
22
Critical Success Factors
Staff vs Machines
• How many staff do I need on site?
– Fleet Size
• • • Qty of PM’s 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
• • • •
23
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
– – – – –
24
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
25
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
26
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 Î 4380 hrs worked 800hrs downtime Î 91% Availability 75% Utilized Î 6570 hrs worked 1200hrs downtime Î 86% Availability
27
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
28
