Documente Academic
Documente Profesional
Documente Cultură
Jim McCaherty
Mining Forum - Peoria
September 23 - 28, 2007
Why do we measure?
Management without metrics is management by intuition.
Why do we measure?
ANSWER: Metrics help us make sense of our
OBSERVATION
Mining equipment management
spends more time reporting
performance than improving
performance.
Objective
Define a process using data that is commonly
available at most sites to develop quantifiable
measures to assess site performance and
identify weak areas, poor practices and other
opportunities for improvement. Use the
process as a Management Tool to prioritize
and attack the key issues affecting
performance.
PHILOSOPHY
Apply what you know to what you would like
to know!
Rebuild Costs
% A/F
Repairs
Design
Quality
Parts
Reuse
Application
Maintenance
Parts
Price
others
Repair Quality
Production
Component Lives
Application
Pit Depth
Haul Distance
Grades
Operation
Op Skill
PLoad
Mgmt.
Bunching
Delays
Blasting
Availability
Availability:
Used to measure performance and
contributions of
Equipment Management
team in support of the
mines production
goals.
HowwellismyMaintenanceorganizationperforming?
Ifmyperformanceissubstandard,
Why?
WhatcanIdotoimproveit?
Availability:
Variations(generalforms):
Physical Availability =
Mechanical Availability =
Contractual Availability =
10
Availability:
Variations(generalforms):
Physical Availability =
Mechanical Availability =
Contractual Availability =
11
Whatistheproblemhere?
Whatistheproblemhere?
Total Calendar Hours Downtime Hours
Availabilitygeneral form =
Availability is driven by ..
Repair Frequency
Repair Duration
Utilization
12
machine reliability
repair quality / maintenance effectiveness
Benchmark = 60 to 80 hours
13
MTBS
14
Operating Hours
number of shutdowns in the period
machine reliability
repair quality / maintenance effectiveness
Benchmark = 60 to 80 hours
15
MTTR
MTTR (hours) =
16
machine reliability
repair quality / maintenance effectiveness
Benchmark = 60 to 80 hours
17
Availability:
Availability general form =
Availability Index =
Availability Index =
18
Reliability &
Repair Effectiveness
Availability Index =
MTBS
MTBS + MTTR
Serviceability &
Repair Efficiency
19
Management Tool
80%
70%
Why MTBS?
60%
50%
40%
30%
20%
10%
0%
0
25
50
75
100
125
150
175
200
MTBS - (hours)
20
MTTR = 3 hrs
MTTR = 6 hrs
MTTR = 9 hrs
MTTR = 12 hrs
Equipment
Disposal
Downtime Reasons
Downtime Major
Characteristics
Detection Routines
Unscheduled
Repairs
Periodic Services
Vital to minimize /
prevent unscheduled
stops
Whos in Control?
Fixed frequency
Must be minimized
Frequency; a function
of MTBS
Negative influence on
MTBS, MTTR &
Availability
The foundation of
efficient / effective
maintenance mgmt.
Scheduled Repairs
(Major & Minor)
A planning window to
keep condition of the
machine at defined level
Frequency determined
by component life targets
& health
Frequency determined
by Planning
Frequency to be
controlled
Impact On
21
Ability to build a
preventive plan
PCR
(Planned Component
Replacement)
Starting point of a
new component life
cycle
Availability
Costs ($)
PCR * X
Downtime Reasons
Detection Routines
Unscheduled
Repairs
Scheduled Repairs
(Major & Minor )
Periodic Services
PCR * X
PCR
Planned Component
Replacement
Preventive Maintenance
First Line
Condition Monitoring
Repair Management
Component Management
Support Processes
22
Parts Management
Performance Evaluation
Evaluation
Backlog Management
Correct / Improve
Continuous Improvement
Training / HR
Why MTBS?
First PCR
cycle
Equipment
Disposal
Downtime Reasons
Detection
Routines
Unscheduled
Repairs
Periodic
Services
Scheduled Repairs
(Major & Minor)
PCR
(Planned
Component
Replacement)
MTBF:
Considers only Failures Unscheduled Repairs (reliability element).
MTBnF:
Considers non-Failures quantifies our efforts in Failure avoidance
(influence reliability).
23
The Relationship:
PCR * X
PHILOSOPHY
Apply what you know to what you would like
to know!
24
What do we know ?
Complete
Start
Repair
CompleteRepair
Repair
Labor
Equipment
ID
Number
Start
Repair
Labor ManManEquipment ID Number
Stop
Code
Stop
Code Reason
Hours
(Date
&&Time)
Hours
Reason
(Date
&
Time)
(Date
Time)
Duration
(Date & Time)
Duration
Equip.
ID
Start Repair
(Date / Time)
Complete Repair
(Date / Time)
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
4/1/03 12:00 AM
4/3/03 7:06 PM
4/3/03 7:33 PM
4/5/03 7:21 AM
4/7/03 9:29 AM
4/8/03 4:42 PM
4/9/03 1:41 AM
4/9/03 1:52 AM
4/9/03 2:17 AM
4/9/03 8:48 PM
4/9/03 9:00 PM
4/10/03 5:02 AM
4/10/03 5:07 AM
4/10/03 6:21 AM
4/10/03 6:26 AM
4/14/03 3:28 PM
4/14/03 3:39 PM
4/14/03 10:54 PM
4/14/03 11:01 PM
4/15/03 2:55 AM
4/15/03 3:23 AM
4/15/03 4:48 AM
4/15/03 4:57 AM
4/15/03 7:35 AM
4/16/03 12:51 PM
4/16/03 12:56 PM
4/17/03 2:13 AM
4/17/03 2:22 AM
4/17/03 9:43 AM
4/17/03 9:58 AM
4/1/03 12:00 AM
4/3/03 7:33 PM
4/5/03 7:21 AM
4/6/03 9:25 PM
4/7/03 11:10 PM
4/8/03 6:02 PM
4/9/03 1:52 AM
4/9/03 2:17 AM
4/9/03 6:24 AM
4/9/03 9:00 PM
4/10/03 3:16 AM
4/10/03 5:07 AM
4/10/03 5:31 AM
4/10/03 6:26 AM
4/10/03 6:42 AM
4/14/03 3:39 PM
4/14/03 9:21 PM
4/14/03 11:01 PM
4/15/03 2:22 AM
4/15/03 3:23 AM
4/15/03 4:11 AM
4/15/03 4:57 AM
4/15/03 5:57 AM
4/15/03 8:05 AM
4/16/03 12:56 PM
4/16/03 1:25 PM
4/17/03 2:22 AM
4/17/03 9:29 AM
4/17/03 9:58 AM
4/17/03 1:09 PM
Stop
Labor
Code
Duration Manhours
0.00
0.44
35.80
38.07
13.67
1.35
0.18
0.41
4.11
0.20
6.27
0.08
0.40
0.08
0.27
0.19
5.69
0.12
3.34
0.48
0.79
0.16
0.99
0.51
0.08
0.48
0.14
7.12
0.25
3.19
0.00
0.00
35.80
76.14
41.00
4.00
0.00
0.41
12.33
0.00
6.27
0.00
0.40
0.00
0.27
0.00
5.69
0.00
3.34
0.00
0.79
0.00
0.99
0.51
0.00
0.48
0.00
7.12
0.00
3.19
1
162
100
111
202
120
162
118
120
162
100
162
128
162
128
162
100
162
100
162
100
162
100
120
162
100
162
100
162
100
Reason
Stop
Stop Scheduled
Scheduled
Service
Meter
Service
Meter
Comments
Comments Reading
Field
Reading
Field/ /Shop
Shop
Comments
comment
Document SMR
Delays
Waiting for Mechanic
Engine
Low engine power
Cooling System
Replace aftercooler gasket
PM
2000 Hr PM
Tires & Rims
Replace tire - position #3
Delays
Waiting for Mechanic
Suspension System
L/F Suspension Noise
Tires & Rims
Replace tire - positions #1 & 2
Delays
Waiting for Mechanic
Engine
Low boost pressure
Delays
Waiting for Mechanic
Cab / Operator Station
Repair L/H Door Lock
Delays
Waiting for Mechanic
Cab / Operator Station
Repair L/H Door Lock
Delays
Waiting for Mechanic
Engine
Engine oil leaks / Low boost pressure
Delays
Waiting for Mechanic
Engine
Low engine power
Delays
Waiting for Mechanic
Engine
Engine derate 30
Delays
Waiting for Mechanic
Air Intake & Exhaust System
Air cleaner plugged
Tires & Rims
Tire Check - Pos. #3
Delays
Waiting for Mechanic
Engine
Low engine oil level
Delays
Waiting for Mechanic
Engine
Engine derate 31
Delays
Waiting for Mechanic
Engine
Engine derate 31
SMR
16214.4
16279.8
16279.8
16279.8
16291.6
16308.7
16316.2
16316.2
16316.2
16330.2
16330.2
16331.9
16331.9
16332.8
16332.8
16434.8
16434.8
16436.4
16436.4
16437.0
16437.0
16437.6
16437.6
16439.1
16467.2
16467.2
16479.7
16479.7
16479.9
16479.9
Stop
Yes
Yes
Yes
Shop /
Field?
Scheduled
N/A
S
S
S
S
S
S
S
S
S
S
F
F
F
F
S
S
S
S
F
F
F
F
F
F
F
S
S
S
S
N/A
No
No
No
Yes
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
25
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
26
Equip.
ID
Start Repair
(Date / Time)
Complete Repair
(Date / Time)
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
HT001
4/1/03 12:00 AM
4/3/03 7:06 PM
4/3/03 7:33 PM
4/5/03 7:21 AM
4/7/03 9:29 AM
4/8/03 4:42 PM
4/9/03 1:41 AM
4/9/03 1:52 AM
4/9/03 2:17 AM
4/9/03 8:48 PM
4/9/03 9:00 PM
4/10/03 5:02 AM
4/10/03 5:07 AM
4/10/03 6:21 AM
4/10/03 6:26 AM
4/14/03 3:28 PM
4/14/03 3:39 PM
4/14/03 10:54 PM
4/14/03 11:01 PM
4/15/03 2:55 AM
4/15/03 3:23 AM
4/15/03 4:48 AM
4/15/03 4:57 AM
4/15/03 7:35 AM
4/16/03 12:51 PM
4/16/03 12:56 PM
4/17/03 2:13 AM
4/17/03 2:22 AM
4/17/03 9:43 AM
4/17/03 9:58 AM
4/1/03 12:00 AM
4/3/03 7:33 PM
4/5/03 7:21 AM
4/6/03 9:25 PM
4/7/03 11:10 PM
4/8/03 6:02 PM
4/9/03 1:52 AM
4/9/03 2:17 AM
4/9/03 6:24 AM
4/9/03 9:00 PM
4/10/03 3:16 AM
4/10/03 5:07 AM
4/10/03 5:31 AM
4/10/03 6:26 AM
4/10/03 6:42 AM
4/14/03 3:39 PM
4/14/03 9:21 PM
4/14/03 11:01 PM
4/15/03 2:22 AM
4/15/03 3:23 AM
4/15/03 4:11 AM
4/15/03 4:57 AM
4/15/03 5:57 AM
4/15/03 8:05 AM
4/16/03 12:56 PM
4/16/03 1:25 PM
4/17/03 2:22 AM
4/17/03 9:29 AM
4/17/03 9:58 AM
4/17/03 1:09 PM
Stop
Labor
Code
Duration Manhours
0.00
0.44
35.80
38.07
13.67
1.35
0.18
0.41
4.11
0.20
6.27
0.08
0.40
0.08
0.27
0.19
5.69
0.12
3.34
0.48
0.79
0.16
0.99
0.51
0.08
0.48
0.14
7.12
0.25
3.19
0.00
0.00
35.80
76.14
41.00
4.00
0.00
0.41
12.33
0.00
6.27
0.00
0.40
0.00
0.27
0.00
5.69
0.00
3.34
0.00
0.79
0.00
0.99
0.51
0.00
0.48
0.00
7.12
0.00
3.19
1
162
100
111
202
120
162
118
120
162
100
162
128
162
128
162
100
162
100
162
100
162
100
120
162
100
162
100
162
100
Reason
Comments
comment
Document SMR
Delays
Waiting for Mechanic
Engine
Low engine power
Cooling System
Replace aftercooler gasket
PM
2000 Hr PM
Tires & Rims
Replace tire - position #3
Delays
Waiting for Mechanic
Suspension System
L/F Suspension Noise
Tires & Rims
Replace tire - positions #1 & 2
Delays
Waiting for Mechanic
Engine
Low boost pressure
Delays
Waiting for Mechanic
Cab / Operator Station
Repair L/H Door Lock
Delays
Waiting for Mechanic
Cab / Operator Station
Repair L/H Door Lock
Delays
Waiting for Mechanic
Engine
Engine oil leaks / Low boost pressure
Delays
Waiting for Mechanic
Engine
Low engine power
Delays
Waiting for Mechanic
Engine
Engine derate 30
Delays
Waiting for Mechanic
Air Intake & Exhaust System
Air cleaner plugged
Tires & Rims
Tire Check - Pos. #3
Delays
Waiting for Mechanic
Engine
Low engine oil level
Delays
Waiting for Mechanic
Engine
Engine derate 31
Delays
Waiting for Mechanic
Engine
Engine derate 31
SMR
16214.4
16279.8
16279.8
16279.8
16291.6
16308.7
16316.2
16316.2
16316.2
16330.2
16330.2
16331.9
16331.9
16332.8
16332.8
16434.8
16434.8
16436.4
16436.4
16437.0
16437.0
16437.6
16437.6
16439.1
16467.2
16467.2
16479.7
16479.7
16479.9
16479.9
Stop
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Shop /
Field?
Scheduled
N/A
S
S
S
S
S
S
S
S
S
S
F
F
F
F
S
S
S
S
F
F
F
F
F
F
F
S
S
S
S
N/A
No
No
No
Yes
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
MTBS
27
What do we need?
MTBS
MTBS (hours) =
MTBS (hours) =
28
Operating Hours
number of shutdowns in the period
3415.77
165
= 20.70 hours
MTTR
29
What do we need?
MTTR
MTTR (hours) =
MTTR (hours) =
30
Downtime Hours
number of shutdowns in the period
838.60
165
= 5.08 hours
Availability Index
Availability Index =
Availability Index =
31
MTBS
MTBS + MTTR
20.70
20.70 + 5.08
= 80.29%
Analysis:
STEP 2:
Analyze
Overall Fleet Performance
32
Interpretation:
33
% Scheduled Downtime .
34
%
Schedule
d
35
What do we need?
%
Schedule
% Scheduled d
Downtime =
% Scheduled Downtime =
168.10
= 20.05%
838.60
STEP 3:
36
Develop
an Action Plan
Recommendations / Action
Plan:
Evaluate / analyze individual machine
performance.
Evaluate / analyze fleet performance on a
component & system basis.
Take steps to increase % Scheduled Downtime.
37
STEP 4:
38
Analysis / Interpretation:
39
Recommendations / Action
Plan:
Use Pareto analysis (significant few / trivial
many)
to identify key problem(s) affecting
truck HT002.
Bring HT002 up to standard to improve overall
fleet performance.
NOTE: Truck HT002 is dragging down the
overall fleet average (-4.85% ).
Apply same approach to another machine.
40
41
42
43
44
STEP 5:
45
Analysis / Interpretation:
Chronic (repetitive) repairs performed on truck
HT002 due to engine and electrical system.
Incorrect problem diagnosis and/or poor repair
execution (redo) are leading to excessive
number of repetitive problems.
NOTE: 85.5% of downtime & 77.8% of
shutdowns
on truck HT002 are due to
engine and electrical
system.
Eliminating redo on HT002 will increase fleet
MTBS
by 41% and reduce fleet downtime
(increase availability) by 31%.
46
STEP 6:
Recommendations / Action
Plan:
Drill down into engine & electrical system
problems to determine root cause(s) of
downtime in those areas.
Train on engine & electrical system diagnostics
/troubleshooting and repair execution.
Consider developing Specialists in these two
critical areas.
STEP 7:
47
Performance
48
Top Problem
Summary
49
Top Problem
Summary
50
Top Problem
Summary
To Calculate Impact on Availability:
=
Total Downtime
(system / component)
Total Downtime
(all causes)
(1 - Availability Index)
(1 - Availability Index)
EXAMPLE:
=
51
(Engine)
Total Downtime
(all causes)
268.97
hours
838.60
hours
=
=
Total Downtime
(1 -.8029)
Top Problem
Summary
STEP 8:
52
Top Problem
Summary
53
Top Problem
Summary
Opportunity to Improve:
= Availability
actual
Availability
reference
EXAMPLE:
Opportunity to Improve = 6.32% 1.61% = 4.71%
54
Analysis / Interpretation:
55
Analysis / Interpretation:
Analysis / Interpretation:
downtime.
scheduled
57
Recommendations / Action
Plan:
Drill down into engine, electrical, cooling &
steering system problems to determine
root cause(s) of downtime in those areas.
Review PM practices time invested in PM is
low &
PM effectiveness is substandard.
Consider:
58
Observations / Recommendations
(general):
59
Start Repair
(Date / Time)
Complete Repair
(Date / Time)
Stop
Labor
Code
Duration Manhours
Reason
Comments
SMR
Stop
Shop /
Field?
Scheduled
60
Questions? /
Comments?
62
END