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Introduction to Performance Metrics
Caterpillar Mining Performance Metrics
Why Performance Metrics?
3
What is a Performance Metric?
4
Targets & Benchmarks
Target:
• A desired internal goal based on needs,
expectations, or commitments
Benchmark:
• An external standard that represents or
quantifies a “best practices” operation or
“best-in-class” performance
5
Key Performance Indicators
6
Student Workbook
7
Exercise 1
Caterpillar Mining Performance Metrics
Key Concepts & Definitions
• Time
• Availability
• Utilization
9
Elements of Time
10
Elements of Time
Unscheduled
Hours
(out of plan)
11
Elements of Time
12
Elements of Time
Downtime Hours
Scheduled & Unscheduled
Maintenance & Repairs
(mechanically unavailable,
not operational) Unscheduled
Hours
(out of plan)
13
Elements of Time
Downtime Hours
Scheduled & Unscheduled
Maintenance & Repairs
(mechanically unavailable,
not operational) Unscheduled
Hours
(out of plan)
Maintenance
& Repairs
14
Elements of Time
Downtime Hours
Scheduled & Unscheduled
Maintenance & Repairs
(mechanically unavailable,
not operational) Unscheduled
Hours
(out of plan)
Delays
Maintenance
& Repairs Repair
Delay Hours
15
Elements of Time
Downtime Hours
Scheduled & Unscheduled
Maintenance & Repairs
(mechanically unavailable,
not operational) Unscheduled
Available Hours
(mechanically Hours
available; (out of plan)
Delays
operational)
Maintenance
& Repairs Repair
Delay Hours
16
Elements of Time
Downtime Hours
Available Hours
Scheduled & Unscheduled
(mechanically
Maintenance & Repairs
available;
(mechanically unavailable,
operational)
not operational) Unscheduled
Hours
(out of plan)
Delays
Stand-by Maintenance
Hours & Repairs Repair
Delay Hours
17
Elements of Time
Downtime Hours
Available Hours
Scheduled & Unscheduled
(mechanically
Maintenance & Repairs
available;
(mechanically unavailable,
operational)
not operational) Unscheduled
Hours
(out of plan)
Delays
18
Elements of Time
Downtime Hours
Available Hours
Scheduled & Unscheduled
(mechanically
Maintenance & Repairs
available;
(mechanically unavailable,
operational)
not operational) Unscheduled
Hours
(out of plan)
Delays Delays
Stand-by Maintenance
Operational Production Hours & Repairs Repair
Delay Hours Delay Hours Delay Hours
19
Elements of Time
Downtime Hours
Available Hours
Scheduled & Unscheduled
(mechanically
Maintenance & Repairs
available;
(mechanically unavailable,
operational)
not operational) Unscheduled
Hours
(out of plan)
Delays Delays
Operating
Hours Stand-by Maintenance
(machine Operational Production Hours & Repairs Repair
working) Delay Hours Delay Hours Delay Hours
20
Stoppages & Shutdowns
21
Availability
• Physical availability
• Mechanical availability
• Contractual availability
22
Physical Availability
23
Mechanical Availability
24
Contractual Availability
25
Utilization
• Asset utilization
• Utilization of availability
26
Asset Utilization
Operating hrs.
Asset utilization =
Total calendar hrs.
27
Utilization of Availability
Operating hrs.
Utilization of availability =
Operating hrs. + Stand-by hrs.
28
Exercise 2
Caterpillar Mining Performance Metrics
Equipment Management Metrics
30
Mean Time Between Shutdowns (MTBS)
Definition:
The average operating time (including production
delays) between machine shutdowns / stoppages
Calculation Formula:
31
Mean Time Between Shutdowns (MTBS)
Data Sources
• Operating hours
– Machine service meter readings
• Production delay hours
– Included in the total operating hours
• Number of shutdowns
– Machine work order history and the
dispatch system
32
Case Study Data
Equip. Stop
Start Repair Complete Repair Code Reason Comments SMR Stop Sch'ld
ID Duration
HT001 4/1/03 12:00 AM 4/1/03 12:00 AM 0.00 1 comment Document SMR 16214.4 N/A
HT001 4/3/03 7:06 PM 4/3/03 7:33 PM 0.44 162 Delays Waiting for Mechanic 16279.8 No
HT001 4/3/03 7:33 PM 4/5/03 7:21 AM 35.80 100 Engine Low engine power 16279.8 No
HT001 4/5/03 7:21 AM 4/6/03 9:25 PM 38.07 111 Cooling System Replace aftercooler gasket 16279.8 Yes No
HT001 4/7/03 9:29 AM 4/7/03 11:10 PM 13.67 202 PM 2000 Hr PM 16291.6 Yes Yes
HT001 4/8/03 4:42 PM 4/8/03 6:02 PM 1.35 120 Tires & Rims Replace tire - position #3 16308.7 Yes No
HT001 4/9/03 1:41 AM 4/9/03 1:52 AM 0.18 162 Delays Waiting for Mechanic 16316.2 No
HT001 4/9/03 1:52 AM 4/9/03 2:17 AM 0.41 118 Suspension System L/F Suspension Noise 16316.2 No
HT001 4/9/03 2:17 AM 4/9/03 6:24 AM 4.11 120 Tires & Rims Replace tire - positions #1 & 2 16316.2 Yes No
HT001 4/9/03 8:48 PM 4/9/03 9:00 PM 0.20 162 Delays Waiting for Mechanic 16330.2 No
HT001 4/9/03 9:00 PM 4/10/03 3:16 AM 6.27 100 Engine Low boost pressure 16330.2 Yes No
HT001 4/10/03 5:02 AM 4/10/03 5:07 AM 0.08 162 Delays Waiting for Mechanic 16331.9 No
HT001 4/10/03 5:07 AM 4/10/03 5:31 AM 0.40 128 Cab / Operator Station Repair L/H Door Lock 16331.9 Yes No
HT001 4/10/03 6:21 AM 4/10/03 6:26 AM 0.08 162 Delays Waiting for Mechanic 16332.8 No
HT001 4/10/03 6:26 AM 4/10/03 6:42 AM 0.27 128 Cab / Operator Station Repair L/H Door Lock 16332.8 Yes No
HT001 4/14/03 3:28 PM 4/14/03 3:39 PM 0.19 162 Delays Waiting for Mechanic 16434.8 No
HT001 4/14/03 3:39 PM 4/14/03 9:21 PM 5.69 100 Engine Engine oil leaks / Low boost pressure 16434.8 Yes No
HT001 4/14/03 10:54 PM 4/14/03 11:01 PM 0.12 162 Delays Waiting for Mechanic 16436.4 No
HT001 4/14/03 11:01 PM 4/15/03 2:22 AM 3.34 100 Engine Low engine power 16436.4 Yes No
HT001 4/15/03 2:55 AM 4/15/03 3:23 AM 0.48 162 Delays Waiting for Mechanic 16437.0 No
HT001 4/15/03 3:23 AM 4/15/03 4:11 AM 0.79 100 Engine Engine derate 30 16437.0 Yes No
33
Mean Time Between Shutdowns (MTBS)
Significance
• A measure of equipment reliability and
maintenance effectiveness
• A measure of machine availability that
incorporates both the frequency and duration
of downtime events
• The single most important measure of equipment
maintenance management performance
34
Mean Time Between Shutdowns (MTBS)
Benchmarks
35
Mean Time Between Shutdowns (MTBS)
Interpretation
• Interpret results monthly and evaluate
6-12 month trends
• MTBS varies significantly from machine
to machine and from day to day
• Analyzing small populations over short
intervals may produce misleading results
36
Mean Time Between Shutdowns (MTBS)
Interpretation
70
60
Target
50
MTBS (hours)
40
30
20
10
0
Nov -02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May -03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03
Month-Year
37
Mean Time To Repair (MTTR)
Definition:
The average downtime for machine stoppages ...
the average duration of downtime events, expressed
in hours
Calculation Formula:
Total downtime hrs.
MTTR (hrs.) =
Number of shutdowns in the period
38
Mean Time To Repair (MTTR)
Data Sources
• Downtime hours: machine work order history and
dispatch system
• Number of shutdowns machine work order history
and dispatch system
39
Mean Time To Repair (MTTR)
Significance
• A performance measure that quantifies repair
turnaround time
• Combines inherent machine maintainability /
serviceability with efficiency of the organization’s
equipment management
40
Mean Time To Repair (MTTR)
Benchmarks
16 Motor Graders --
41
Mean Time To Repair (MTTR)
Interpretation
• A gauge of product serviceability and ability of
equipment management organization to influence
end result
• High MTTR symptomatic of low availability
• Can be used to identify sources of delays
42
Mean Time To Repair (MTTR)
Interpretation
6
MTTR (hours)
5
Target Range
4
0
Nov -02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May -03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03
Month-Year
43
Mean Time To Repair (MTTR)
Interpretation
100%
80%
Availability
60%
40%
20%
0%
2 4 6 8 10 12
MTTR (hours)
44
Availability Index
Definition:
The ratio of MTBS to the sum of MTBS and MTTR,
expressed as a percentage
Calculation Formula:
MTBS
Availability index (%) = X 100
MTBS + MTTR
45
Availability Index
Data Sources
• Same data sources as MTBS and MTTR
46
Availability Index
Significance
• Availability calculations vary greatly from
site to site
• A “normalized” variation that can be used for
comparison and benchmarking
• Ignores stand-by hours where equipment is
available for operation, but not utilized
47
Availability Index
Benchmarks
48
Availability Index
Interpretation
35 98%
30 96%
MTBS / MTTR (hours)
20 92%
15 90%
10 88%
Target Availability Index
5 86%
0 84%
Nov -02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May -03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03
Month-Year
49
Availability Index
Interpretation
Percentage
75%
Hours
60 70%
65%
40 60%
55%
20 50%
45%
0 40%
Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep
Month
50
Exercise 3
Caterpillar Mining Performance Metrics
% Scheduled Downtime
Definition:
The percentage of total downtime hours performed in
a given period that have been planned and scheduled
Calculation Formula:
52
% Scheduled Downtime
Data Sources
• Total downtime hours: machine work order history
and dispatch system
• Scheduled downtime hours: machine work
order history
53
Stop Duration Times
Equip. Stop
Start Repair Complete Repair Code Reason Comments SMR Stop Sch'ld
ID Duration
HT001 4/1/03 12:00 AM 4/1/03 12:00 AM 0.00 1 comment Document SMR 16214.4 N/A
HT001 4/3/03 7:06 PM 4/3/03 7:33 PM 0.44 162 Delays Waiting for Mechanic 16279.8 No
HT001 4/3/03 7:33 PM 4/5/03 7:21 AM 35.80 100 Engine Low engine power 16279.8 No
HT001 4/5/03 7:21 AM 4/6/03 9:25 PM 38.07 111 Cooling System Replace aftercooler gasket 16279.8 Yes No
HT001 4/7/03 9:29 AM 4/7/03 11:10 PM 13.67 202 PM 2000 Hr PM 16291.6 Yes Yes
HT001 4/8/03 4:42 PM 4/8/03 6:02 PM 1.35 120 Tires & Rims Replace tire - position #3 16308.7 Yes No
HT001 4/9/03 1:41 AM 4/9/03 1:52 AM 0.18 162 Delays Waiting for Mechanic 16316.2 No
HT001 4/9/03 1:52 AM 4/9/03 2:17 AM 0.41 118 Suspension System L/F Suspension Noise 16316.2 No
HT001 4/9/03 2:17 AM 4/9/03 6:24 AM 4.11 120 Tires & Rims Replace tire - positions #1 & 2 16316.2 Yes No
HT001 4/9/03 8:48 PM 4/9/03 9:00 PM 0.20 162 Delays Waiting for Mechanic 16330.2 No
HT001 4/9/03 9:00 PM 4/10/03 3:16 AM 6.27 100 Engine Low boost pressure 16330.2 Yes No
HT001 4/10/03 5:02 AM 4/10/03 5:07 AM 0.08 162 Delays Waiting for Mechanic 16331.9 No
HT001 4/10/03 5:07 AM 4/10/03 5:31 AM 0.40 128 Cab / Operator Station Repair L/H Door Lock 16331.9 Yes No
HT001 4/10/03 6:21 AM 4/10/03 6:26 AM 0.08 162 Delays Waiting for Mechanic 16332.8 No
HT001 4/10/03 6:26 AM 4/10/03 6:42 AM 0.27 128 Cab / Operator Station Repair L/H Door Lock 16332.8 Yes No
HT001 4/14/03 3:28 PM 4/14/03 3:39 PM 0.19 162 Delays Waiting for Mechanic 16434.8 No
HT001 4/14/03 3:39 PM 4/14/03 9:21 PM 5.69 100 Engine Engine oil leaks / Low boost pressure 16434.8 Yes No
HT001 4/14/03 10:54 PM 4/14/03 11:01 PM 0.12 162 Delays Waiting for Mechanic 16436.4 No
HT001 4/14/03 11:01 PM 4/15/03 2:22 AM 3.34 100 Engine Low engine power 16436.4 Yes No
HT001 4/15/03 2:55 AM 4/15/03 3:23 AM 0.48 162 Delays Waiting for Mechanic 16437.0 No
HT001 4/15/03 3:23 AM 4/15/03 4:11 AM 0.79 100 Engine Engine derate 30 16437.0 Yes No
54
% Scheduled Downtime
Significance
• Used to assess the effectiveness of maintenance
and repair planning
• High % scheduled downtime indicates inefficient
use of resources
• Many sites experience eight times more
unscheduled downtime than scheduled
• Key measure of equipment maintenance
management performance
55
% Scheduled Downtime
Benchmarks
• Large mining trucks (785 – 793 class): 80% in
well-managed operations
• Other production mining equipment should have
similar metrics; non-production equipment
somewhat less
56
% Scheduled Downtime
Interpretation
30%
25%
Trend
20%
(rolling average)
15%
10%
5%
0%
Jun-99 Jul-99 Aug-99 Sep-99 Oct-99 Nov-99 Dec-99 Jan-00 Feb-00 Mar-00 Apr-00 May-00
Month-Year
57
Asset Utilization
Definition:
The proportion of time that a machine is operating
(operating hours) divided by the total calendar time in
the period, expressed as a percentage
Calculation Formula:
Operating hrs.
Asset utilization (%) = X 100
Total calendar hrs.
58
Asset Utilization
Data Sources
• Operating hours: machine service
meter readings
• Total calendar hours: total time in the
period analyzed
59
Asset Utilization
Significance
• High utilization makes maintenance and repairs
scheduling more difficult, requiring close
coordination between production and equipment
management operations
• Objective is to achieve high availability, good
reliability, and the lowest possible cost per unit
of production
60
Asset Utilization
Benchmarks
• Organizations with effective equipment
management operations achieve 90% utilization
on large mining trucks
• This benchmark is probably applicable for other
production equipment; non-productive equipment
may be slightly less
61
Asset Utilization
Interpretation
95%
90%
85%
80%
75%
70%
Oct-02 1 Dec-02
2 3Jan-034 Mar-03
5 6May-037 Jun-03
8 9Aug-0310 Oct-03
11 12Nov-03
Month-Year
62
Maintenance Ratio
Definition:
The dimensionless ratio of maintenance and repair
man-hours to machine operating hours
Calculation Formula:
63
Maintenance Ratio
Data Sources
• Maintenance & repair man-hours: work
order history
• Operating hours: machine service meter reading
64
Maintenance Ratio
Significance
• Indicates level of effort required to keep equipment
in service
• Effectiveness of maintenance operation
• Can be calculated as “charged” or “direct”
65
Maintenance Ratio
Benchmarks
66
Maintenance Ratio
Interpretation
Maintenance Ratio
793 Mining Trucks Fleet
1.0 1.3
0.9 1.2
0.8 1.1
0.7 1.0
0.6 0.9
0.5 0.8
0.4 0.7
0.3 0.6
Benchmark Range
0.2 0.5
0.1 0.4
0.0 0.3
Jun-99 Jul-99 Aug-99 Sep-99 Oct-99 Nov-99 Dec-99 Jan-00 Feb-00 Mar-00 Apr-00 May-00
Month-Year
67
Exercise 4
Caterpillar Mining Performance Metrics
Top Problems / Pareto Analysis
Definition:
The distribution of problems affecting a fleet of
equipment ranked in terms of MTBS, MTTR, impact
on availability and costs
Calculation Formula:
Operating hrs.
MTBS (by system) =
Number of shutdowns (by system)
Downtime hrs.
MTTR (by system) =
Number of shutdowns (by system)
69
Top Problems / Pareto Analysis
Data Sources
• Operating hours: service meter reading
• Number of shutdowns: machine work order history
and dispatch system
• Downtime hours: machine work order history and
dispatch system
• Cost: may or may not be available at
your dealership
70
Top Problems / Pareto Analysis
Significance
• Clear understanding of problems is necessary to
establish equipment management priorities
• Identification and quantification of top problems by
system helps correctly focus limited resources
71
Top Problems / Pareto Analysis
Benchmarks
• Generic references available from Caterpillar
• Enables project management to identify and
prioritize critical issues
• Relatively small minority of issues typically causes
majority of grief on a project
72
Top Problems / Pareto Analysis
Interpretation
73
PIP / PSP Completion Status
Definition:
A tracking tool used to monitor the status of
implementation of factory programs
Calculation Formula:
74
PIP / PSP Completion Status
Data Sources
• Technical communications staff
• Machine history
75
PIP / PSP Completion Status
Significance
• Factory-sponsored fixes and improvements
to base machine design
• Usually applicable to a defined serial
number range
• May be deployed on a before or after
failure basis
• Usually issued with 12-month timeframe
for implementation
76
PIP / PSP Completion Status
Benchmarks
• Compliance with program recommendations is
viewed as critical to project success
• No program should be permitted to run beyond its
termination date without being addressed unless it
is an after-failure only program
77
PIP / PSP Completion Status
Interpretation
• Low program completion percentages, programs
approaching termination date, or programs not
planned and scheduled are all indicative of poor
management practices
• Correlation of incomplete programs to top
problems analysis should generate reprioritization
of maintenance schedules
78
Exercise 5
Caterpillar Mining Performance Metrics
Operations Management Metrics
80
Fuel Consumption
Definition:
The fuel consumption (average engine fuel burn rate)
for a fleet of equipment, expressed in volume (gallons
or liters) per hour
Calculation Formula:
81
Fuel Consumption
Data Sources
• Fuel consumption: VIMS, ECM, or other machine
fueling records
• Operating hours: machine service meter readings
82
Fuel Consumption
Significance
• Application severity in mines changes over time
with changes to haul distances and grades
• Variation in application severity produces variation
in fuel consumption
• Fuel burn rate will signal needed changes to
maintenance strategies
83
Fuel Consumption
Benchmarks
• No external benchmarks
• Compare to historical data or projections from
FPC or Mine EIA
84
Fuel Consumption
Interpretation
240
230
220
210
200
190
Fuel Rate (l/hr)
Month-Year
85
Payload Management
Definition
• An analysis of payload distribution for a fleet of
mining trucks expressed in terms of Caterpillar's
10/10/20 truck overload policy
• “The mean (average) of the payload distribution
shall not exceed the target payload, no more than
10% of payloads may exceed 1.1 times the target
payload, and no single payload shall ever exceed
1.2 times the target payload”
86
10/10/20 Truck Overload Policy
90% of loads should fall into this range
• No more than 10% of loads above 1.10
No more than 10% of loads should
• No loads above 1.20 exceed 110% of the target payload
• The average payload shall not exceed the target No loads should be above 120% of
the target payload
Durability
SAFETY
Productivity
Number of Loads
90 % 10%
80 85 90 95 100 105 110 115 120
% of Target Payload
87
Payload Management
Data Sources
• Gross machine weights: Cat Performance
Handbook, machine specification sheets, factory
documentation
• Payload data: TPMS, VIMS-TPMS reports
88
Payload Management
Significance
• Helps determine if truck operation is within safe
and commercially acceptable limits
• Pressure to reduce truck-loader pass match
usually results in higher operating costs
89
Payload Management
Significance
90
Payload Management
Benchmarks
• Best documented performance is a
standard deviation equal to 6 ½ percent
of the target payload
• Payload management helps the
equipment manager adapt or modify
his maintenance strategy
91
Payload Management
Interpretation
Weights in 797B 793C 793C 789C 785C
Kilograms Flat Floor Dual Slope Flat Floor Dual Slope Dual Slope
Gross Machine 249,476
623,690 383,739 383,739 317,515
Operating Weight
Empty Machine
274,670 165,599 160,835 137,450 109,241
Weight (Std.)
Empty Machine
265,145 151,899 151,899 125,899 100,541
Weight (MSD)
PAYLOADS IN
METRIC TONS
Target Payload (Std.) 349 218 223 180 140
Target Payload
359 232 232 192 149
(MSD)
Max Gross Payload
(Std.)10/10/20 Limit 419 262 267 216 168
(not to exceed)
Max Gross Payload
(MSD)10/10/20 Limit 430 278 278 230 179
(not to exceed)
Maximum Do-Not-
696,264 431,457 431,457 356,342 279,957
Ever-Exceed GMW
92
Payload Management
Interpretation
93
Haul Cycle Detail
Definition:
An analysis of the operations on a particular haul
road layout for a fleet of mining trucks that enables
the equipment manager to isolate the most
significant factors affecting overall fleet performance
and costs
Calculation Formula:
Total empty distance + Total loaded distance
Average haul cycle distance =
Number of loads
Data Sources:
• Truck Payload Management System (TPMS)
• VIMS-TPMS reports
95
Haul Cycle Detail
Significance
• Application severity of mining trucks directly
related to haul cycle details
• Haul cycle analysis can help avoid
premature failures
• Adjusting haul cycle details to benefit
production can have negative impact on
machine performance and cost
96
Haul Cycle Detail
Benchmarks
• Practical limits apply to operational parameters
such as speeds, grades, and haul distances
• Output of fleet production and cost (FPC) and
other application modeling software can be used
as targets
97
Haul Cycle Detail
Interpretation
• Analyze all detected changes in haul cycle details
in context of their potential influence on machine
condition and performance
98
Haul Cycle Detail
Interpretation
15
14
13
12
Time (minutes)
11
10
9
8
7
6
5
May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Jan-04 Feb-04 Mar-04 Apr-04
Month-Year
Loaded Travel Time Idle Time Empty Travel Time
99
Haul Cycle Detail
Interpretation
15 280
14
13 260
12
Time (minutes)
100
MARC / Customer Satisfaction
101
Contractual Availability
Definition:
The ratio of time that a machine is capable of
functioning in the intended operation (available hours)
to total calendar hours in the period under
consideration, expressed as a percentage.
The calculation of available hours is not a pure
calculation since the result is amended by downtime
hours that are specifically excluded or limited by the
terms of the contract
Calculation Formula:
Total calendar hrs. – MARC downtime hrs.
Contractual availability (%) = X 100
Total calendar hrs.
102
Contractual Availability
Data Sources:
• Total calendar hours: total time in period
to be analyzed
• MARC downtime hours: machine work order
history and dispatch system
103
Contractual Availability
Significance
• Contracts ensure a specified level of availability,
enabling mines to meet production goals at a
predetermined operating cost
• Variations in contracts from site to site
• Contracts often place limits or caps on delays over
which the contractor has little control
104
Contractual Availability
Benchmarks
• Benchmarks or site-to-site comparisons are
impractical because of variations in contract
exclusions and limitations
• Target performance to contract definitions
and customer expectations
105
Contractual Availability
Interpretation
40 100%
30 96%
MTBS / MTTR (hours)
25 94%
20 92%
15 90%
10 88%
5 86%
0 84%
Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03
Month-Year
106
Putting It All Together
Caterpillar Mining Performance Metrics
Mean Time Between Shutdowns (MTBS)
108
Mean Time To Repair (MTTR)
109
Availability Index
110
% Scheduled Downtime
111
Asset Utilization
112
Maintenance Ratio
113
Top Problems / Pareto Analysis
114
Top Problems / Pareto Analysis
Is Impacted By:
• Maintenance strategy, ... a repair-before-failure
strategy focused on early detection and failure
avoidance plays a fundamental role in problem
management, i.e., condition monitoring (quality
and quantity of inspections), planning &
scheduling, backlog management, etc.
• Maintenance execution, ... resources (facilities and
manpower) in adequate numbers and of sufficient
quality have a direct influence on the end results
• Application severity, ... drives the results
e.g., excessive fuel burn rate will tend to
magnify engine-related downtime, overloading
will accelerate power train and structural
deterioration, etc.
• Operating environment, ... haul road conditions,
ambient temperature extremes and precipitation all
have a role in determining which areas on the
machine will experience problems
115
PIP / PSP Completion Status
116
Fuel Consumption
117
Fuel Consumption
Is Impacted By:
• Mine maturation, ... application severity as
indicated by increases in fuel burn rate will
increase as the mine develops, e.g., pit depth
(maximum vertical lift) and haul distances increase
• Mine operating efficiencies, ... application severity
as indicated by increases in fuel burn rate will
increase with the addition of dispatch systems or
loading tools, i.e., reductions in idle or wait time
will result in increases in fuel burn rate
• Fuel system operation, ... a malfunctioning fuel
system on one or more machines may produce
false indications of change in application severity
in terms of fuel burn rate
118
Payload Management
119
Payload Management
120
Payload Management
Is Impacted By:
• Payload measurement system operation, ... any
malfunction of the pay load measurement system,
e.g., system calibration, strut charge, strut sensor
operation, etc., on one or more machines will
result in erroneous load data that will produce
false indications of change in for the fleet
• Mine production requirements, ... an availability
shortfall or increase in the production demand may
result in intentional overloading in the interest of
short-term production gains
• Operating practices, ... backing onto the toe of the
cut, load placement in the dump body, and
tamping the load with the loader bucket will impact
payload measurement system accuracy
• Material density, ... normal variations in material
density as well as those that result from variability
in seasonal precipitation, i.e., material moisture
content, will complicate payload management
control practices
121
Payload Management
Is Impacted By:
• Truck-loader pass match, ... while it may yield
short-term production advantages, three to four
pass loading will make the task of payload
management much more difficult
• Bucket fill factor, ... muck pile variation that results
from blasting practices and / or material loadability
as well as normal variations in loader operator
skill levels may create problems for
payload management
• Bucket-dump body capacity, ... loader buckets that
incorrectly sized to the dump body will result in
problems for payload management
122
Haul Cycle Detail
123
Haul Cycle Detail
124
Haul Cycle Detail
Is Impacted By:
• Mine maturation process, ... as mines mature haul
cycle distances tend to become longer and pits
become deeper (increased vertical lift). As
a result, the impact of the application becomes
more severe in terms of its influence on fleet
performance and costs
• Grades, ... application severity increases as
grades and the percentage of time on
grade increase
• Haul road maintenance, ... substandard haul road
surfaces and increases in rolling resistance have
adverse affects on travel speeds, production and
application severity
• Dispatch system, ... the addition of a dispatch
system should reduce the amount of idle time
that the fleet sees. Thus, as dispatch
improves operational
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Contractual Availability
126
Using KPIs to Analyze & Manage Mine Performance
Case Study
Questions
Caterpillar Mining Performance Metrics