maintenance & repair costs - jones
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EAME Miners Forum Malaga - 2007
Mining expertise,
business solutions
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Financial Management of Equipment
Evaluating Maintenance & Repair Costs
Direct Equipment Costs
Expenditures against equipment as a result ofPlanned Maintenance, Breakdown or PreventativeMaintenance
In-Direct Equipment Costs
Expenditures undertaken to support and facilitate
fleet maintenance; on-site & off-site
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In-Direct Machine Financial Requirements
Off-Site Support Staffing
Set Up Costs
Tooling
Service Vehicles
On-Site Support Critical Success Factors
Planning
Component Inventory
Parts Inventory
Losses
Consumable Inventory
Non Cat Parts Sourcing
Continuous Improvement
Technical Support
Warranty
Financial Management
Business System
Rebuild Logistics
Inventory Management
Safety
HR & Payroll
Logistics
Management Tree
Training
Staff Recruitment
Staff vs Machines
Early SMU Management
Crane Availability
Fuel Truck Availability
Components vs Machines
Component Planning
Utilization vs. Maintenance
Component Life
Operation Severity
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Set Up Costs
Mining normally in Remote Location
Internet connection
V-SAT
Maintenance of communicatiions
On Site IT Computers
Laptops
Workshop Set Up
Consumable Dispensing Units
Lubricant Suction Units Air Lines
Demarcation Lines
CC & Safety Signage
PM Bay Set Up
Walk Around PM Stand
Kidney Loop Equipment Integration
Drip Trays
Tooling Cabinets and Tool Boxes
Workbenches
On Site Support
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Set up Costs
Oil Dispensing Units
Environmentally complying Cubes
Fine in-line filtration
Pump
Consumables Wash Bay Facility
Pressurized Water Supply allowinglocalized and efficient washing
Office Facility
Furniture
IT Printers, Scanners etc.
Cupboards, cabinets
Planning Boards
On Site Support
i
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Tooling
Tooling provided to all employees?
Finance Costs
Specialised Tooling Requirements
Lost / Replacement tooling
Tooling Supply Lifting Chain Safety Requirements
Non Cat Tooling Sourcing
Tooling Supply
Depreciation
Finance Charge
On Site Support
O Sit S t
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Service Vehicles
Mobile Fueling Truck
In pit daily servicing
Daily Inspection of machines
Lubricant and Coolant supply
Selection Mobility Speed
Reliability
Supply
Spare parts & Stocking
Light Vehicles
Fleet Coverage
On Board Tooling Requirement
Maintenance
Parts Supply and Stocking
On Site Support
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Service Vehicles
Specialised Support Equipment
Telehandlers
Facility Manoeuvrability
Component Replacement
Man Basket Function
Fork Lift Parts and Component Manoeuvrability
General Workshop use
Hiab Truck
Component replacement
Heavy / Large item transport
Specialised Maintenance Equipment Welding Bay
Mobile / Stationary Welding Sets
Work benches
Compressor
Mobile / Stationary
Air supply in field
On Site Support
On Site Support
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Planning
Storage of WIP (Backlog) Parts
Shelving
Plastic Boxes
Clipboards
Warehouse space
Planning Visual Aids
Component Planning Boards
PM planning Boards
Information Storage
Business Dealer System
Capture planning functions
Machine History Files
Storage Room
On Site Support
On Site Support
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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
Charges
Finance Cost
Depreciation
Component Space Allocation
Rust Prevention
Forklift Access
On Site Support
On Site Support
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Consumable Inventory & Losses
Lubricant Grease, Oil & Coolant
Finance Costs
Logistics
Welding Consumables Nitrogen & Oxygen Bottles
Grinding Discs
Welding Rods
Workshop Consumables Rags
Contamination Control Wipes
Mats
Stationary Printed Forms
Printer paper and cartridges
Theft
Dead Stock
Wastage Oil & Fuel
Incorrectly ordered parts
Warranty Claims
Poor Workmanship
On Site Support
On Site Support
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Safety
Personal Protective Equipment
Vests
Boots
Glasses
Hats
Welding Screens
Vehicle Safety Enhancements
Flashing Lights
Buggy Whips
ROPS
Fleet Safety Enhancements
Mounting and Dismounting Standards
Lock Out Devices
Wheel Chocks
Lifting Device Certification and Training
Chains Periodic Inspection Crane Inspection and Certification
Lifting Training
On Site Support
On Site Support
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Operation Severity
Operation Severity Measurement
Consistency
Key Performance Indicators
Operator Influence
Long Term Abuse Transmission Shifting Retarder Control
Torque Stall
Pit Floor / Haulroad Influence
Fleet Life
Labour Hour Calculations Workshop Space Calculations
Tyre Maintenance
Loading Practices influence
Strut Maintenance
Body Maintenance
Tyre Maintenance
On Site Support
Off Site Support
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Inventory Management & Non Cat Parts Sourcing
Central Inventory Control Initial inventory stocking
Min / Max Setting
Re-ordering metrics
Parts Clearing
In country logistics Fast Moving Parts
GET Management Cost / Hour
Hrs / Change
Undercarriage Management
CTS Inspections Wear rates
Shoe Life
Link Life
Roller Life
Frame Life
Non CAT Sourcing Mega Water Truck Spares
Service Truck Spares
Fork Lift Parts
pp
Off Site Support
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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
pp
Off Site Support
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Business System and Financial Management
Parts and Work Order Management
Parts Requests and Additions
Work Order Opening
Invoicing Requirements
Cost Control
Scheduled Reporting
Work in Progress
Backlog Parts
Non-moving Parts
Fleet Costs Management
Expenditure versus Budget
Projected Costs
High Costing Machine Areas
Machine Specific Reports
Re-alignment of maintenance practicesalong with expenditures
Off Site Support
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Rebuild Logistics
Component Return
to M.A.R.C. Site
Planned / Unplanned
Component Replacement
C.R.C. Strip,
Rebuild & Test
(Following R.P.I.
Administration)
Component delivery to
C.R.C. Workshop
(Component Tags and
Repair Instructions)
The 3 week
Component ReturnCycle
Fleet Long Life
Component Projections
Pre-Prepared 100%
Rebuild Kits
Pre-Ordering 100%
Kits for all Components
(Seafreight)
Pre-Prepared Labour
Enhancements and
Structure Upgrade
1
2monthPla
nningproces
s
Staffing
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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
Staffing
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Management Structure
Project Manager
Maintenance PlannerSHEMaintenance Supervisor Parts Supervisor
Welding Supervisor Electrical SupervisorService Bay Supervisor Shift Supervisor
Abraham SackeyAlfred TawiahSamuel Ayiku
Francis GyakyeAlex Baah
Kwasi AmandeIsaac Nyarko
Emmanuel EwudziDominic CudjoeAsare Baidoo
Benjamin AhorseyBuami Xola
GeorgeNkrumahCyrusSampson Larbi
Daniel AcheampongLawrencia Ofosu Gyan
Martin SateklaGabriel Cudjoe
Hagar NyamekyeKofi Gyimah
Thomas AppiahLawrence Mensah
Ebenezer OppongChristian KumordziAnthony Aquach
George Blay
Workshop Supervisor
Admin Manager
Terrence BlanksonDaniel Adjah
John Oko AmarteifioSamuel Okine
Fred AkuffoEmmanuel AmuCharles Mends
William Asare DonkorEmmanuel Bart-Plange
J ames Abban (C)James Asamoah (C)
Isaac ObengAbdul Karim
Nicholas KueviFuseini Amandu
Moses AtivoRichard Kofi Norgbey
Samuel DanquahAgbessi BamideleKingsley AppiahRichard Nyanney
James BiliniSamuel ArthurBekai DarkuJ ohnTanko
AyubaBen VondeyMaxwell Boaitey
Fuel Bay InspectorsDan Venance
Samuel IncoomPaul Bluvi
Prince Yeboah
Lord Cudjoe Lub e TruckEdward Kwame Kyi
Akakpo MichaelFranklin KwofiePeter Danso
William AmpahPatrick Boakye
CIL Inspectors
George SolomonRichard Mensah
J ohn Kyei Bosco
Samuel Boadi BramscoIsaac Kyereboah
Wilson Vordzorgbe
J ohn OpokuEmmanuel Nsiah Adams
Gaddiel AmoakoYussif SeiduAlfred Yankson
Vehicle Info Manager
Hose Technician
Rowland Bessieh
Crane operators
Ebenezer Asimeng
Wakson Supervisor
Seidu DawudaIbrahim Abubakari
Francis KwofieAugustine TsiwahJoel Ankomal
lBen TakyiKwesi Ano
Staffing
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Logistics
Transport
Staff transport to/from work
Expatriate travel to/from site forleave/training
Leave / Training Flights
Visitor travel arrangements External trainers
Accommodation
On site accommodation for expatriate staff
Furniture
Kitchen Utensils
Cleaning and Laundry
Hotels
Local accommodation for training
Visitor and Management Hotel Costs
Food
Local Food supply Dayshift/Nightshift
Expatriate Meals
Visitor / Management Meals
Staffing
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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
Critical Success Factors
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Components vs. Machines
How many spare components do I needon 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 10Equipment Models
>90% Availability
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Staff vs Machines
How many staff do I need on site?
Fleet Size
Qty of PMs per day
Average Breakdowns per day
Component Changeouts per day
Fleet Age Proximity to Component Changeouts
Specialised Work Required
Welders (Body repairs)
Breakdown % per day
Workmanship
Quality of work
Scope Capabilities
Training Needs
Key Areas
PM Supervisor
Toolstore
Backlog Store
Maintenance Planner
Critical Success Factors
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Component Life & Planning
Component Life Extention
Increasing component life does not meandecreasing cost per hour
Increasing component life and achieving budgetedrebuild costwill decrease cost per hour
Rear Axle Life
Kidney Looping
Condition Monitoring
Oil Cleanliness
High efficient filters
Continuous Monitoring
Fleet SMU Proximity Implication
Try to avoid Component Change-Out Peaks
Be aware of the possibility of component potentialfailure increase.
Plan 12 months in advance
Ensure Parts and Rebuild Centres are aware
Replacement Strategy
Remanoption Recondition option
New option
After/ Before Failure option
Condition Monitoring option
Critical Success Factors
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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 thebreakdown
Ensure Systems and Procedures areadhered 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
Critical Success Factors
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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
Critical Success Factors
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Utilization vs Availability
Projected utilization of fleet key to facilityand maintenance planning
Components
Staff
Workshop Space
Tooling
Rebuild Centres
Utilization is directly proportionate tomachine downtime
Availability in relation to calendar hours
will vary due to machine utilization Example
8760hrs Calender Hours
50% Utilized 4380 hrs worked
800hrs downtime 91% Availability
75% Utilized 6570 hrs worked
1200hrs downtime 86% Availability
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In-Direct Machine Financial Requirements
Off-Site Support Staffing
Set Up Costs
Tooling
Service Vehicles
On-Site Support Critical Success Factors
Planning
Component Inventory
Parts Inventory
Losses
Consumable Inventory
Non Cat Parts Sourcing
Continuous Improvement
Technical Support
Warranty
Financial Management
Business System
Rebuild Logistics
Inventory Management
Safety
HR & Payroll
Logistics
Management Tree
Training
Staff RecruitmentStaff vs Machines
Early SMU Management
Crane Availability
Fuel Truck Availability
Components vs Machines
Component Planning
Utilization vs. Maintenance
Component Life
Operation Severity