Drive Maintenance Performance with Data Metrics

Maintenance Performance Metrics
Using Data to Drive Decisions
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
situation; we become smarter and

gain some degree of control over
the outcome.
OBSERVATION
Mining equipment management
spends more time reporting
performance than improving
performance.
Reports serve three primary

purposes:
to provide basic performance information to top
management,
management,
to identify problems or needed action, and
to set priorities for the problem management
(continuous
improvement) process.
* Onlythelattertwoprovideinformationthatdirectlyhelpstoimprovetheoperation.
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.
Why use Performance Metrics?

____________
To assign and fix blame.
To assess, quantify and document as is performance
relative to internal targets and established benchmarks.
To highlight shortcomings and opportunities for improvement
relative to design, application and maintenance.
To establish priorities in the deployment of resources.
etc.
PHILOSOPHY
Apply what you know to what you would like
to know!
What would you like to

know?
from
Cost
/ Hour
Rebuild Costs
% A/F
Repairs
Cost / Ton perspective

a Maintenance
Tons / Hour
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.
What would you like to

know?
HowwellismyMaintenanceorganizationperforming?
Ifmyperformanceissubstandard,
Why?
WhatcanIdotoimproveit?
Availability:
Variations(generalforms):
Physical Availability =
Mechanical Availability =
Contractual Availability =
10
Total Calendar Hours all Downtime Hours

Total Calendar Hours
Total Calendar Hours mechanical Downtime Hours
Total Calendar Hours MARC Downtime Hours
Availability:
Variations(generalforms):
Physical Availability =
Mechanical Availability =
Contractual Availability =
11
Scheduled Hours all Downtime Hours

Scheduled Hours
Scheduled Hours mechanical Downtime Hours
Scheduled Hours
Scheduled Hours MARC Downtime Hours
Scheduled Hours
Whatistheproblemhere?
Whatistheproblemhere?
Total Calendar Hours Downtime Hours
Availabilitygeneral form =
Availability is driven by ..
Repair Frequency
Repair Duration
Utilization
12
Identify Key Performance

Indicators & Establish
Repair FrequencyBenchmarks:
. MTBS (Mean Time Between Shutdowns)
machine reliability
repair quality / maintenance effectiveness
Benchmark = 60 to 80 hours
13
MTBS
(Mean Time Between Shutdowns)
Defines the frequency of machine downtime

events;
an indication of inherent machine
reliability &
equipment management
effectiveness.
MTBS (hours) =
14
Operating Hours
number of shutdowns in the period

machine reliability
Repair Duration ... MTTR (Mean Time To Repair)

machine serviceability
repair timeliness / maintenance efficiency
15
MTTR
(Mean Time To Repair)
Defines the average duration of machine

downtime events; an indication of machine
serviceability
& equipment management efficiency.
MTTR (hours) =
16
Total Downtime Hours


machine reliability
Repair Duration ... MTTR (Mean Time To Repair)

machine serviceability
repair timeliness / maintenance efficiency
Utilization Operated Hours / Available Hours

Results are determined by Operations
NOT Maintenance
17
Availability:
Availability general form =
Availability Index =
Operating Hours + Stand-By Hours

Operating Hours + Stand-By Hours + Downtime Hours
Operating Hours
Operating Hours + Downtime Hours
Operating Hrs / Shutdowns
Operating Hrs / Shutdowns + Downtime Hrs / Shutdowns
Availability Index (%) = (MTBS / (MTBS + MTTR))*100
18

Benchmarks:
Reliability &
Repair Effectiveness
MTBS
MTBS + MTTR
Serviceability &
Repair Efficiency
Defines a normalized availability KPI by ignoring the

effects
of utilization.
Benchmark = 88 to 92%.
19
Availability Index is the Availability
Management Tool
Availability Index & MTBS

100%
90%
Availability Index - (%)
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 = 4.5 hrs
MTTR = 6 hrs
MTTR = 7.5 hrs
MTTR = 9 hrs
MTTR = 12 hrs
Maintenance & Repair Management Scenario

First PCR
cycle
Equipment
Disposal
Machine Life Cycle

(Based on PCR)
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
Well known routine
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
Window used for

restoring machine to
standard
Frequency to be
controlled
Impact On
21
Ability to build a
preventive plan
MTBS, MTTR &

maintenance plan
PCR
(Planned Component
Replacement)
Starting point of a
new component life
cycle
Availability
Ability to maintain the

maintenance plan
Costs ($)
PCR * X
Maintenance & Repair Management Scenario
Downtime Reasons
Detection Routines
Unscheduled
Repairs
Scheduled Repairs
(Major & Minor )
Periodic Services
PCR * X
PCR
Planned Component
Replacement
Maintenance Management Process
Preventive Maintenance
First Line
Condition Monitoring
Repair Management
Component Management
Planning & Scheduling
Support Processes
22
Parts Management
Performance Evaluation
Evaluation
Backlog Management
Correct / Improve
Continuous Improvement
Training / HR
Why MTBS?
First PCR
cycle
Equipment
Disposal
Machine Life Cycle

(Based on PCR)
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:
1 / MTBS = 1 / MTBF + 1 / MTBnF
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
Suspension System
L/F Suspension Noise
Tires & Rims
Replace tire - positions #1 & 2
Delays
Engine
Low boost pressure
Delays
Cab / Operator Station
Repair L/H Door Lock
Delays
Delays
Engine
Engine oil leaks / Low boost pressure
Delays
Engine
Low engine power
Delays
Engine
Engine derate 30
Delays
Air Intake & Exhaust System
Air cleaner plugged
Tires & Rims
Tire Check - Pos. #3
Delays
Engine
Low engine oil level
Delays
Engine
Engine derate 31
Delays
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
Scope & Goals of Project
25
Yes
Yes
Yes
Small fleet of 793 OHTs

Availability Target = 88%
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
The process - STEP 1:
Evaluate Overall Fleet Performance
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
Engine
Low engine power
Cooling System
PM
2000 Hr PM
Tires & Rims
Replace tire - position #3
Delays
Suspension System
Tires & Rims
Replace tire - positions #1 & 2
Delays
Engine
Low boost pressure
Delays
Delays
Delays
Engine
Engine oil leaks / Low boost pressure
Delays
Engine
Low engine power
Delays
Engine
Engine derate 30
Delays
Air Intake & Exhaust System
Air cleaner plugged
Tires & Rims
Delays
Engine
Delays
Engine
Engine derate 31
Delays
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
3415.77
165
= 20.70 hours
MTTR
29
What do we need?
MTTR
MTTR (hours) =
MTTR (hours) =
30
Downtime Hours
838.60
165
= 5.08 hours
Availability Index
31
MTBS
MTBS + MTTR
20.70
20.70 + 5.08
= 80.29%
Analysis:
Overall fleet performance is substandard

Availability Index = 80.29%.
MTTR is within acceptable limits (5.08 hours),
MTBS is too low (20.70 hours).
STEP 2:
Analyze
Overall Fleet Performance
32
Interpretation:
Overall fleet performance is substandard

MTTR is within acceptable limits (5.08 hours).
MTBS is cause of low availability.
33

Benchmarks:
% Scheduled Downtime .
Defines the extent that Equipment

Management is in control of
the situation vs. reacting to it.
Effectiveness of the Equipment
Management system.
Benchmark = 80% of all DT is
planned & scheduled.
% Scheduled Downtime =
34
Scheduled Downtime Hours

%
Schedule
d
35
What do we need?
%
Schedule
% Scheduled d
Downtime =
% Scheduled Downtime =
Scheduled Downtime Hours

168.10
= 20.05%
838.60
Low MTBS is result of unscheduled downtime.
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:
Evaluate Individual Machine

Performance
38
Analysis / Interpretation:
Truck No. HT002 is performing well below the

average of the rest of the fleet.
54 shutdowns in one month (30 days).
39
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
Pareto Analysis HT002
41
Pareto Analysis HT002
42

43

44
STEP 5:
Analyze Truck HT002 Performance
45
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:
Develop an Action Plan
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
Evaluate Component / System
Performance

Top Problem Summary
.
Benchmarks:
48
Enables Equipment Management

to identify the most significant issues
and focus its resources on their
containment & resolution.
Rule of Thumb: Apply Pareto
analysis; information must be
quantified and compared against
historical performance and / or
established references.
Target: All downtime is documented by
cause and in terms of frequency,
duration and cost of each repair.
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)
6.32% (impact of engines on fleet availability)
Top Problem
Summary
STEP 8:
52
Analyze Component / System

Performance
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
Pareto applies Top four issues (20%) account for 73.5% of

all
downtime (14.5% lost availability).
Opportunity to improve > 12%.
55
Time invested in PM is low (70% of reference).

Inadequate PM time is likely contributing to very low fleet
MTBS.
MTBS
NOTE:
after PM (PM quality / effectiveness) is low (30

hours).
56
Delays are a chronic problem (100 events) but the impact

on
availability is minimal (0.65%).
Substantial number of delays is due to low percentage of
downtime.
scheduled
57
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
Random post-PM audits,

Reducing PM interval to 250 hours,
Revising PM checklists to emphasize top
Minimize issues.
or eliminate delays through improved
Condition Monitoring (defect detection)

increase MTBS & % Scheduled Downtime.
Observations / Recommendations
(general):
Highly utilized fleet performing poorly.
Maintenance organization is extremely reactive; operation

is out of
control.
Percentage of scheduled downtime is very low (20% by
hours /
4.2% by event.
PM and Condition Monitoring functions are substandard.
Information management is ineffective not learning from
failures.
Invest in efforts to put management in control of the
operation.
Reinforce / emphasize PM & Condition Monitoring practices.
Learn from failures Past performance is frequently a
valid predictor of future behavior !
59
Which method is your

organization using?
Equip.
ID
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
Start Repair
(Date / Time)
Complete Repair
(Date / Time)
Stop
Labor
Code
Duration Manhours
Reason
Comments
SMR
Stop
Shop /
Field?
Scheduled
4/1/03 12:00 AM 4/1/03 12:00 AM

0.00
0.00
1
comment
Document SMR
16214.4
N/A
N/A
4/3/03
7:06 PMStart 4/3/03
0.00
Delays
16279.8
S
No /
Equip.
Repair7:33 PM
Complete 0.44
Repair
Stop 162
Labor
Shop
CodeEngine
Reason
SMR S Stop No
Scheduled
4/3/03 ID
7:33 PM(Date 4/5/03
35.80
100
Low engine powerComments 16279.8
/ Time)7:21 AM(Date / 35.80
Time)
Duration
Manhours
Field?
4/5/03 7:21 AM
4/6/03 9:25 PM
38.07
76.14
111
Cooling System
16279.8 Yes
S
No
HT001 4/1/03 12:00 AM 4/1/03 12:00 AM
0.00
0.00
1
comment
Document SMR
16214.4
N/A
N/A
4/7/03 9:29 AM
4/7/03 11:10 PM
13.67
41.00
202
PM
2000 Hr PM
16291.6 Yes
S
Yes
HT001 4/3/03 7:06 PMStart 4/3/03
7:33 PM
0.44
Delays
16279.8
S
No /
Repair 1200.00
Stop 162
Labor
Shop
4/8/03 4:42 PM Equip.
4/8/03 6:02 PMRepair 1.35Complete4.00
Tires
& RimsCode
Replace
tire
position
#3
16308.7
Yes
S
No
Reason
SMR S Stop No
Scheduled
HT001 4/3/03ID
7:33 PM(Date 4/5/03
7:21 AM
35.80
35.80
100
Engine
Low engine powerComments 16279.8
Time) 162
Duration
Manhours
Field?
4/9/03 1:41 AM
4/9/03 1:52
AM/ Time) 0.18 (Date /0.00
Delays
16316.2
S
No
HT001 4/5/03 7:21 AM
4/6/03 9:25 PM
38.07
76.14
111
Cooling System
16279.8 Yes
S
No
4/9/03 1:52 AM HT001
4/9/03 2:17
AM
0.41 AM 118 0.00 Suspension
16316.2 SMR
S
No
4/1/03
12:00 AM0.41 4/1/03 12:00
0.00 System
1
comment
Document
16214.4
N/A
N/A
HT001 4/7/03 9:29 AM
4/7/03 11:10 PM
13.67
41.00
202
PM
2000 Hr PM
16291.6 Yes
S
Yes
4/9/03 2:17 AM HT001
4/9/03 6:24
AM7:06 PM4.11
Tires
& Rims 162Labor
Replace
tire - positions #1 & 2 Waiting
16316.2
Yes
S
No
4/3/03
4/3/0312.33
7:33 PM 120 0.44
0.00
Delays
for Mechanic
16279.8
S
No /
Start
Repair 120
Stop
Shop
HT001 4/8/03 4:42 PM Equip.
4/8/03 6:02
PMRepair 1.35Complete
4.00
Tires & RimsCode
Replace
tire
position
#3
16308.7
Yes
S
No
Reason
SMR S Stop No
Scheduled
4/9/03 8:48 PM HT001
4/9/03 9:00
PMID
0.20 4/5/03
0.00 AM 162 35.80
Delays Manhours
16330.2
S
No
4/3/03
7:33 PM(Date
7:21
35.80
100
Engine
Low
engine powerComments
16279.8
Time) 162Duration
Field?
HT001 4/9/03 1:41 AM
4/9/03 1:52
AM/ Time) 0.18 (Date /0.00
Delays
16316.2
S
No
4/9/03 9:00 PM HT001
4/10/03 3:16
AM
Engine 111
LowSystem
boost pressure
16330.2
Yesgasket S
No Yes
4/5/03
7:21 AM6.27 4/6/03 6.27
9:25 PM 100 38.07
76.14
Cooling
Replace
aftercooler
16279.8
S
No
HT001 4/9/03 1:52 AM HT001
4/9/03 2:17
AM
0.41 AM 118 0.00 Suspension
16316.2 SMR
S
No
4/1/03
12:00 AM0.41 4/1/03 12:00
0.00 System
1
comment
Document
16214.4
N/A
N/A
4/10/03 5:02 AM HT001
4/10/03 5:07
AM
0.00 PM 162 13.67
Delays 202
Waiting
16331.9
F
No Yes
4/7/03
9:29 AM0.08 4/7/03 11:10
41.00
PM for Mechanic
2000 Hr PM
16291.6
S
Yes
HT001 4/9/03 2:17 AM HT001
4/9/03 6:24
AM7:06 PM4.11 4/3/0312.33
Tires
Replace
tire - pos itions #1 & 2 Waiting
16316.2
Yes
S
No
4/3/03
7:33 PM 120 0.44
0.00& Rims 162
Delays
for Mechanic
16279.8
S
No
4/10/03 5:07 AM HT001
4/10/03 5:31
AM
Repair
L/H Door Lock Replace
16331.9
Yes #3 F
No Yes
4/8/03
4:42 PM0.40 4/8/03 0.40
6:02 PM 128 1.35 Cab / Operator
4.00 Station
120
Tires
& Rims
tire - position
16308.7
S
No
HT001 4/9/03 8:48 PM HT001
4/9/03 9:00
PM7:33 PM0.20 4/5/03 7:21
0.00 AM 162 35.80
Delays 100
16330.2
S
No
4/3/03
35.80
Engine
Low
engine power
16279.8
S
No
4/10/03 6:21 AM HT001
4/10/03 6:26
AM
0.00 AM 162 0.18
Delays 162
16332.8
No
4/9/03
1:41 AM0.08 4/9/03 1:52
0.00
Delays
Waiting
for Mechanic F
16316.2
S
No
HT001 4/9/03 9:00 PM HT001
4/10/03 3:16
AM
Engine 111
LowSystem
boost pressure
16330.2
Yesgasket S
No Yes
4/5/03
7:21 AM6.27 4/6/03 6.27
9:25 PM 100 38.07
76.14
Cooling
Replace
aftercooler
16279.8
S
No
4/10/03 6:26 AM HT001
4/10/03 6:42
AM
0.27 AM 128 0.41 Cab / Operator
RepairSystem
L/H Door Lock
16332.8 Yes
No
4/9/03
1:52 AM0.27 4/9/03 2:17
0.41 Station
118
Suspension
L/F Suspension
Noise F
16316.2
S
No
HT001 4/10/03 5:02 AM HT001
4/10/03 5:07
AM
0.00 PM 162 13.67
Delays 202
Waiting
16331.9
F
No Yes
4/7/03
9:29 AM0.08 4/7/03 11:10
41.00
PM for Mechanic
2000 Hr PM
16291.6
S
Yes
4/14/03 3:28 PM HT001
4/14/03 4/9/03
3:39 PM2:17 AM0.19 4/9/03 6:24
0.00 AM 162 4.11
Delays 120
Waiting
No Yes
12.33
Tires
& Rimsfor Mechanic Replace16434.8
tire - positions #1 & S2
16316.2
S
No
HT001 4/10/03 5:07 AM HT001
4/10/03 5:31
AM
Repair
L/H Door Lock Replace
16331.9
Yes #3 F
No Yes
4/8/03
4:42 PM0.40 4/8/03 0.40
6:02 PM 128 1.35 Cab / Operator
4.00 Station
120
Tires
& Rims
tire - position
16308.7
S
No
4/14/03 3:39 PM HT001
4/14/03 9:21
PM8:48 PM5.69 4/9/03 5.69
Engine 162
Engine oil
leaks / Low boost pressure
16434.8
Yes
S
No
4/9/03
9:00 PM 100 0.20
0.00
Delays
Waiting
for Mechanic
16330.2
S
No
HT001 4/10/03 6:21 AM HT001
4/10/03 6:26
AM
0.00 AM 162 0.18
Delays 162
16332.8
No
4/9/03
1:41 AM0.08 4/9/03 1:52
0.00
Delays
Waiting
for Mechanic F
16316.2
S
No
4/14/03 10:54 PM HT001
4/14/03 11:01
Delays 100
16436.4
No Yes
4/9/03PM
9:00 PM0.12 4/10/030.00
3:16 AM 162 6.27
6.27
Engine
Low
boost pressure S
16330.2
S
No
HT001 4/10/03 6:26 AM HT001
4/10/03 6:42
AM
0.27 AM 128 0.41 Cab / Operator
RepairSystem
L/H Door Lock
16332.8 Yes
No
4/9/03
1:52 AM0.27 4/9/03 2:17
0.41 Station
118
Suspension
L/F Suspension
Noise F
16316.2
S
No
4/14/03 11:01 PM HT001
4/15/034/10/03
2:22 AM5:02 AM3.34 4/10/033.34
Engine 162
Low engine power
16436.4
Yes
S
No
5:07 AM 100 0.08
0.00
Delays
Waiting
for Mechanic
16331.9
F
No
HT001 4/14/03 3:28 PM HT001
4/14/03 4/9/03
3:39 PM2:17 AM0.19 4/9/03 6:24
0.00 AM 162 4.11
Delays 120
Waiting
No Yes
12.33
Tires
& Rimsfor Mechanic Replace16434.8
tire - positions #1 & S2
16316.2
S
No
4/15/03 2:55 AM HT001
4/15/034/10/03
3:23 AM5:07 AM0.48 4/10/030.00
Delays 128
WaitingStation
for Mechanic
16437.0
No Yes
5:31 AM 162 0.40
0.40
Cab / Operator
Repair
L/H Door Lock F
16331.9
F
No
HT001 4/14/03 3:39 PM HT001
4/14/03 9:21
PM8:48 PM5.69 4/9/03 5.69
Engine 162
Engine oil
leaks / Low boost pressure
16434.8
Yes
S
No
4/9/03
9:00 PM 100 0.20
0.00
Delays
Waiting
for Mechanic
16330.2
S
No
4/15/03 3:23 AM HT001
4/15/034/10/03
4:11 AM6:21 AM0.79 4/10/030.79
Engine 162
Engine derate 30
16437.0
Yes
F
No
6:26 AM 100 0.08
0.00
Delays
Waiting
for Mechanic
16332.8
F
No
HT001 4/14/03 10:54 PM HT001
4/14/03 11:01
Delays 100
16436.4
No Yes
4/9/03PM
9:00 PM0.12 4/10/030.00
3:16 AM 162 6.27
6.27
Engine
Low
boost pressure S
16330.2
S
No
4/15/03 4:48 AM HT001
4/15/034/10/03
4:57 AM6:26 AM0.16 4/10/030.00
Delays 128
WaitingStation
for Mechanic
16437.6
No Yes
6:42 AM 162 0.27
0.27
Cab / Operator
Repair
L/H Door Lock F
16332.8
F
No
HT001 4/14/03 11:01 PM HT001
4/15/034/10/03
2:22 AM5:02 AM3.34 4/10/033.34
Engine 162
Low engine power
16436.4
Yes
S
No
5:07 AM 100 0.08
0.00
Delays
Waiting
for Mechanic
16331.9
F
No
4/15/03 4:57 AM HT001
4/15/03 4/14/03
5:57 AM3:28 PM0.99 4/14/030.99
Air Intake 0.00
& Exhaust 162
System
Air cleaner plugged
16437.6
Yes
F
No
3:39 PM 100 0.19
Delays
Waiting
for Mechanic
16434.8
S
No
HT001 4/15/03 2:55 AM HT001
4/15/034/10/03
3:23 AM5:07 AM0.48 4/10/030.00
Delays 128
WaitingStation
for Mechanic
16437.0
No Yes
5:31 AM 162 0.40
0.40
Cab / Operator
Repair
L/H Door Lock F
16331.9
F
No
4/15/03 7:35 AM HT001
4/15/03 4/14/03
8:05 AM3:39 PM0.51 4/14/030.51
Tires
Tire Check - Pos. #3Engine oil leaks
16439.1
F
No Yes
9:21 PM 120 5.69
5.69& Rims 100
Engine
/ Low Yes
boost pressure
16434.8
S
No
HT001 4/15/03 3:23 AM HT001
4/15/034/10/03
4:11 AM6:21 AM0.79 4/10/030.79
100
Engine
Engine
derate
30
16437.0
Yes
F
No
6:26 AM
0.08
0.00
162
Delays
16332.8
F
No
4/16/03 12:51 PM HT001
4/16/034/14/03
12:56 PM
Delays 162
16467.2
No
10:54 PM0.08 4/14/03 0.00
11:01 PM 162 0.12
0.00
Delays
Waiting
for Mechanic F
16436.4
S
No
HT001 4/15/03 4:48 AM HT001
4/15/034/10/03
4:57 AM6:26 AM0.16 4/10/030.00
Delays 128
WaitingStation
for Mechanic
16437.6
No Yes
6:42 AM 162 0.27
0.27
Cab / Operator
Repair
L/H Door Lock F
16332.8
F
No
4/16/03 12:56 PM HT001
4/16/034/14/03
1:25 PM11:01 PM0.48 4/15/030.48
Engine 100
16467.2
Yes
F
No Yes
2:22 AM 100 3.34
3.34
Engine
Low
engine power
16436.4
S
No
HT001 4/15/03 4:57 AM HT001
4/15/03 4/14/03
5:57 AM3:28 PM0.99 4/14/030.99
Air Intake &
Exhaust 162
System
Air cleaner plugged
16437.6
Yes
F
No
3:39 PM 100 0.19
0.00
Delays
Waiting
for Mechanic
16434.8
S
No
4/17/03 2:13 AM HT001
4/17/034/15/03
2:22 AM2:55 AM0.14 4/15/030.00
Delays 162
16479.7
No
3:23 AM 162 0.48
0.00
Delays
Waiting
for Mechanic S
16437.0
F
No
HT001 4/15/03 7:35 AM HT001
4/15/03 4/14/03
8:05 AM3:39 PM0.51 4/14/030.51
Tires
Tire Check - Pos. #3Engine oil leaks
16439.1
F
No Yes
9:21 PM 120 5.69
5.69& Rims 100
Engine
/ Low Yes
boost pressure
16434.8
S
No
4/17/03 2:22 AM HT001
4/17/034/15/03
9:29 AM3:23 AM7.12 4/15/037.12
100
Engine
Engine
derate
31
16479.7
Yes
S
No
4:11 AM
0.79
0.79
100
Engine
Engine derate 30
16437.0 Yes
F
No
HT001 4/16/03 12:51 PM HT001
4/16/034/14/03
12:56 PM
Delays 162
16467.2
No
10:54 PM0.08 4/14/03 0.00
11:01 PM 162 0.12
0.00
Delays
Waiting
for Mechanic F
16436.4
S
No
4/17/03 9:43 AM HT001
4/17/034/15/03
9:58 AM4:48 AM0.25 4/15/030.00
Delays 162
16479.9
No
4:57 AM 162 0.16
0.00
Delays
Waiting
for Mechanic S
16437.6
F
No
HT001 4/16/03 12:56 PM HT001
4/16/034/14/03
1:25 PM11:01 PM0.48 4/15/030.48
Engine 100
16467.2
Yes
F
No Yes
2:22 AM 100 3.34
3.34
Engine
Low
engine power
16436.4
S
No
4/17/03 9:58 AM HT001
4/17/034/15/03
1:09 PM4:57 AM3.19 4/15/033.19
Engine 100 Air Intake & Exhaust
Engine derate
Yes
S
No Yes
5:57 AM 100 0.99
0.99
System31
Air16479.9
cleaner plugged
16437.6
F
No
HT001 4/17/03 2:13 AM HT001
4/17/034/15/03
2:22 AM2:55 AM0.14 4/15/030.00
Delays 162
16479.7
No
3:23 AM 162 0.48
0.00
Delays
Waiting
for Mechanic S
16437.0
F
No
HT001 4/15/03 7:35 AM 4/15/03 8:05 AM
0.51
0.51
120
Tires & Rims
16439.1 Yes
F
No
HT001 4/17/03 2:22 AM HT001
4/17/034/15/03
9:29 AM3:23 AM7.12 4/15/037.12
Engine 100
Engine derate 31
16479.7derate
Yes30
S
No Yes
4:11 AM 100 0.79
0.79
Engine
Engine
16437.0
F
No
HT001 4/16/03 12:51 PM 4/16/03 12:56 PM
0.08
0.00
162
Delays
16467.2
F
No
HT001 4/17/03 9:43 AM HT001
4/17/034/15/03
9:58 AM4:48 AM0.25 4/15/030.00
Delays 162
16479.9
No
4:57 AM 162 0.16
0.00
Delays
Waiting
for Mechanic S
16437.6
F
No
HT001 4/16/03 12:56 PM 4/16/03 1:25 PM
0.48
0.48
100
Engine
16467.2 Yes
F
No
HT001 4/17/03 9:58 AM HT001
4/17/034/15/03
1:09 PM4:57 AM3.19 4/15/033.19
Engine 100 Air Intake & Exhaust
Engine derate
Yes
S
No Yes
5:57 AM 100 0.99
0.99
System31
Air16479.9
cleaner plugged
16437.6
F
No
HT001 4/17/03 2:13 AM 4/17/03 2:22 AM
0.14
0.00
162
Delays
16479.7
S
No
HT001 4/15/03 7:35 AM 4/15/03 8:05 AM
0.51
0.51
120
Tires & Rims
Tire Check - Pos . #3
16439.1 Yes
F
No
HT001 4/17/03 2:22 AM 4/17/03 9:29 AM
7.12
7.12
100
Engine
Engine derate 31
16479.7 Yes
S
No
HT001 4/16/03 12:51 PM 4/16/03 12:56 PM
0.08
0.00
162
Delays
16467.2
F
No
HT001 4/17/03 9:43 AM 4/17/03 9:58 AM
0.25
0.00
162
Delays
16479.9
S
No
HT001 4/16/03 12:56 PM 4/16/03 1:25 PM
0.48
0.48
100
Engine
16467.2 Yes
F
No
HT001 4/17/03 9:58 AM 4/17/03 1:09 PM
3.19
3.19
100
Engine
Engine derate 31
16479.9 Yes
S
No
HT001 4/17/03 2:13 AM 4/17/03 2:22 AM
0.14
0.00
162
Delays
16479.7
S
No
HT001 4/17/03 2:22 AM 4/17/03 9:29 AM
7.12
7.12
100
Engine
Engine derate 31
16479.7 Yes
S
No
HT001 4/17/03 9:43 AM 4/17/03 9:58 AM
0.25
0.00
162
Delays
16479.9
S
No
HT001 4/17/03 9:58 AM 4/17/03 1:09 PM
3.19
3.19
100
Engine
Engine derate 31
16479.9 Yes
S
No
60
Questions? /
Comments?
Key Points / Take-Aways

Use Data to develop Information for use as Management
Tools,
Apply meaningful Equipment Management metrics to
quantify
performance,
Analyze / Interpret Information to define critical issues,
Understand the big picture & what is driving the end
results
Drill Down into issues by fleet / individual
machine /
systems,
Build action-oriented plans to address the key issues.
62
END

Drive Maintenance Performance with Data Metrics

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Maintenance Performance Metrics

Using Data to Drive Decisions

situation; we become smarter and

Reports serve three primary

Why use Performance Metrics?

What would you like to

Cost / Ton perspective

What would you like to

Total Calendar Hours all Downtime Hours

Scheduled Hours all Downtime Hours

Total Calendar Hours

Identify Key Performance

(Mean Time Between Shutdowns)

Defines the frequency of machine downtime

Identify Key Performance

Repair Duration ... MTTR (Mean Time To Repair)

(Mean Time To Repair)

Defines the average duration of machine

Total Downtime Hours

Identify Key Performance

Repair Duration ... MTTR (Mean Time To Repair)

Utilization Operated Hours / Available Hours

Operating Hours + Stand-By Hours

Operating Hrs / Shutdowns + Downtime Hrs / Shutdowns

Availability Index (%) = (MTBS / (MTBS + MTTR))*100

Identify Key Performance

Defines a normalized availability KPI by ignoring the

Availability Index is the Availability

Availability Index & MTBS

Availability Index - (%)

MTTR = 4.5 hrs

MTTR = 7.5 hrs

Maintenance & Repair Management Scenario

Machine Life Cycle

Well known routine

Window used for

MTBS, MTTR &

Ability to maintain the

Maintenance & Repair Management Scenario

Maintenance Management Process

Planning & Scheduling

Machine Life Cycle

1 / MTBS = 1 / MTBF + 1 / MTBnF

Scope & Goals of Project

Small fleet of 793 OHTs

The process - STEP 1:

Evaluate Overall Fleet Performance

Overall fleet performance is substandard

Overall fleet performance is substandard

Identify Key Performance

Defines the extent that Equipment

Scheduled Downtime Hours

Scheduled Downtime Hours

Low MTBS is result of unscheduled downtime.

Evaluate Individual Machine

Truck No. HT002 is performing well below the

54 shutdowns in one month (30 days).

Pareto Analysis HT002

Pareto Analysis HT002

Analyze Truck HT002 Performance

Develop an Action Plan

Evaluate Component / System