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Caterpillar & Dealers (Gmmco, TIPL)Supporting CIL’s 1 Billion Ton+ roadmap
Pinaki Chatterjee20 Jan 2015
2 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
• Estd. in 1925 as Caterpillar Tractor Co.• HQ - Peoria, Illinois State, USA• Manufacturing of earthmoving & mining
equipment, diesel & gas engines and also involved in the financial products business
• 110,000+ employees WW
• 88+ years of dealer network history– 178 dealerships WW, 160,000+ dealer employees– $ 21.8 Bill dealer net worth
OUR COMPANY - CATERPILLAR
3 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
• Gmmco– Established in 1967, HQ- Chennai– Turnover ~ US $ 400 Mill– 28+ years of association with Caterpillar as dealer– Manages 8200 machines & 8300 engines in its territory
• TIPL, a subsidiary of TIL– TIL established in 1945, TIPL in Apr 2010 to exclusively handle Cat portfolio– HQ - Kolkata– TIPL turnover ~ US $ 250 Mill.– 70+ years with Caterpillar as dealer– Manages 8000 machines & 7200 engines
• www.caterpillar.com, www.cat.com, www.gmmco.in, www.tiplindia.in
OUR INDIA DEALERS – Gmmco, TIPL
4 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
• INDUSTRIES– Mining– Construction– Electric Power Generation– Locomotive & Railway– Oil & Gas– Paving– Quarry, Aggregates and Cement– Marine– Material Handling– Pipeline– Forestry– Demolition and Scrap Recycling– Waste– Agriculture– Landscaping– Governmental & Defence– OEM Solutions– Power Plants
INDUSTRIES WE SERVE, OTHER SERVICE AREAS
• SERVICE AREAS– Technology & Solutions– Rental– Maintenance and Repair– Financing– Insurance– Remanufacturing
5 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
BROADEST PRODUCT LINE IN THE MINING INDUSTRY
6 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
MACHINE RANGES - SURFACE
MINING TRUCKS / DUMPERS
40 / 50 / 60 / 70 / 100 / 150 / 190 / 240/ 320 / 350 / 400 (tons)
ELECTRIC ROPE
SHOVELS
50 ton : 19-38 cu.m. / 70 ton : 20 – 55 cu.m. / 90-120 ton : 27 – 62 cu.m.
HYDRAULIC SHOVELS
105 ton (6 cu.m.) / 180 ton (10 cu.m.) / 300 ton (17 cu.m.) / 407 ton (22 cu.m.) / 535 ton (28 cu.m.) / 570 ton (34 cu.m.)
WHEEL LOADERS
290 hp (4-4.5 cu.m.) / 350 hp (4.8-5.4 cu.m.) / 540 hp (5.4-5.8 cu.m.) / 410 hp (6.2 cu.m.) / 625 hp (7.5 cu.m.) / 815 hp (10 cu.m.) / 1025 hp (13 cu.m.) / 1460 hp (17 cu.m.)
DRAGLINES76 – 96 m (20-32 cu.m.) / 100 m (41-61 cu.m.) / 110 – 132.5 m (76-116 cu.m.)
ROTARY BLAST HOLE
DRILLS
(270 mm, 55.5 m max, 48 cum/min) / (311 mm, 74.4 m max, 67.9 cum/min) / (381 mm, 84.7 m max, 102 cum/min) / (406 mm, 42.7 m max, 107.6 cum/min) / (444 mm, 39.6 m max, 108 cum./min)
7 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
MACHINE RANGES - SURFACE
TRACK DOZERS 300 hp, 410 hp, 600 hp, 850 hp
WHEEL DOZERS 355 hp, 500 hp, 630 hp, 815 hp
MOTOR GRADERS 14 ft, 16 ft, 24 ft blade
HIGHWALL MINERS
305 m (28-38” dia drum, 2.95-3.5 m drum width, 8-10 deg pit floor, 8 deg max. seam gradient)
BELT CONVEYORS 1800-2200 tph / 9000 tph
8 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
MACHINE RANGES – UG - CM
CONTINUOUS MINERS .81m – 4.7 m seam heights,
FEEDER BREAKERS 860, 1150, 1390 tph
FACE HAULERS,
CONTINUOUS HAULAGE
Battery (10, 19 tons), Diesel (22 tons)Cont. Haulage – 20, 30 tph
ROOF BOLTERS
(under devl.)Upto 2.3 m drill boom feed,
UTILITY VEHICLES (SCOOPS,
LHD)
Scoops carrying capacity – 7 to 16 tonsLHD – 2.7 cu.m. (8,10 tonnes payload), 3.5 cu.m. (10 tonnes), 4.5 cu.m. (15 tonnes),
BELTS 1800-2200 tph / 9000 tph
9 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
MACHINE RANGES – UG - PSLW
SHEARERS1.8 – 7 m seam heights, upto 45m/min cutting speed (Max. 5000 tph), Single, Double & Three drum shearers
PLOWS 0.8 – 2.3 m, upto 3.6 m/s travel speeds, Max. 3500 tph
ROOF SUPPORTS .5 m – 6.1 m, Upto 111 tonne/sqm shield density
ROOF SUPPORT CARRIERS
40 – 60 tons payload capacity
ARMOURED FACE
CONVEYOR SYSTEMS
Upto 500 m length, 660 - 6200 tph
BEAM STAGE LOADERS Line pan (2000-7000 tph), Crusher (1500-8000 tph),
CST DRIVE SYSTEMS 300,000 Nm – 1150,000 Nm Torque
AUTOMATION
10 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
MANUFACTURING FACILITIES WORLDWIDE
Caterpillar Global MiningHeadquartersWISCONSIN, US
Draglines & Electric Rope Shovels
WISCONSIN, USA
Excavators, Wheel Loaders & Wheel Dozers
ILLINOIS, USA
Track-Type Tractors,Mining Trucks, Motor Graders
& ScrapersILLINOIS, USA
DrillsTEXAS, USA
Mining TrucksMEXICO
Truck BodiesMEXICO
Motor GradersARKANSAS, USA
Hard RockUnderground
BRAZIL
Room & Pillar, Longwall, Highwall, Conveyors EASTERN
USA
Longwall, Hard Rock Underground,
& Hydraulic ShovelsGERMANY
LongwallCZECH REPUBLIC
ArticulatedTrucks
UNITED KINGDOM
Mining TrucksRUSSIA
Truck BodiesRUSSIA
LongwallCHINA
Hard RockUnderground
THAILAND
Hard RockUnderground
TASMANIA
Truck BodiesINDONESIA
Mining TrucksINDIA
Map is for illustrative purposes and is not intended to reflect every facility
11 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
CAPACITIES
USA Decatur 150+ ton Trucks > 1500 / yr
- Do - 24 ft Motor Graders > 130 / yr
South Milwaukee Electric Rope Shovels, Draglines
ERS : > 20 / yr ; DGL : Custom
Aurora Wheel Loaders, Wheel Dozers WL : > 800 / yr ; WD : 200 / yr
Texas RBH Drills > 70 / yr
East Peoria Track Dozers > 1800 / yr
Arkansas 14, 16 ft Motor Graders > 350 / yr
Pennsylvania Highwall Miner ~ 5 / yr
- Do - Continuous Miners, Feeder Breaker, Roof Bolter
CM : > 20 / yr
Virginia Belt Conveyors
GERMANY Lunen Longwall Custom
Dortmund Hydraulic Mining Shovels > 125 / yr
AUSTRALIABeresfield Diesel Coal Hauler, Utility
Vehicle
INDIA Thiruvallur 60, 100 ton Trucks > 1000 / yr
12 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
TECHNOLOGY
• Product Link– Remote monitoring / Asset Tracking through
Cellular communication– Secure web based solution– Insight into machine operation, health,
productivity– Customisable, maintenance alerts can be set– Few features visible are machine working
hours, fuel consumption, physical location,
13 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
• Service Support– Troubleshooting & Product Problem Resolution– Condition Monitoring Services– Technical Audit Services– Custom Hydraulic Services– Custom Track Services– Component/ Sub Assembly exchange programs
– Guaranteed availability contracts– Parts cap / cost cap guarantee contracts
• > 130 machines– MARCs (Full Maintenance & Repair)
• 255+ machines, including 240 ton trucks, 42 cu.m. ERS, 34 cu.m. HMS
– Customer Infrastructure consultation• Gevra workshop for 240 ton trucks
AFTER SALES SUPPORT
14 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
• Service Support– Sub assembly repairs, Major component
repairs• 5 workshops, Nagpur, Chennai, Asansol, Delhi,
Udaipur. Some are 5 & 4 Cat certified• Machine Power train rebuild & test bench facility
– Machine rebuilds• Nagpur & Asansol Machine Rebuild Centre
– SOS (Scheduled Oil Sampling)
AFTER SALES SUPPORT
15 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
AFTER SALES SUPPORT
• Parts Support– Infrastructure
• 80 Warehouses, 5 Main depots, > 86,000 lie items• Inventory > INR 375 cr• Contamination Control certified stores• Online connectivity between various dealer
branches as well as various Cat parts distribution facilities
• Online transaction processing• Dealer Stock service level > 92%
– Parts cap / cost cap guarantee contracts– Component / Sub Assembly exchanges– MARCs (Full Maintenance & Repair)– Spares Depot Agreements / Rate Contracts
16 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
AFTER SALES SUPPORT
• Service Training - Customer– Classroom– Training lab– Field– NPI / NMI
• Operator Training– Classroom– Simulator– In-the-iron (machine)
17 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
AFTER SALES SUPPORT
• Skill building– Mining machine operator bank– Mechanical & electrical technician training at school levels– A “desired place to work” environment to attract and retain talent
18 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
OUR THOUGHTS …
• INCREASING PRODUCTION– Increasing machine utilisation
• Product Link technology deployment• Analysis of operating hours leakages
– Usage of Electrically powered Hydraulic Mining Shovels• Faster equipment• Using existing electrical infrastructure• Controlling input fuel costs (diesel vs electricity)
19 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
OUR THOUGHTS …
• INCREASING PRODUCTION
– Enhance usage of Highwall Miners– Adopt Plow technology for UG coal in thin seams below 1.5m– Use of appropriate mining equipment having long term
replacement cycles• Long term outsourcing contracts
– Consignment spares stocks in each subsidiary HQ– Combining OC mines & even in UG operations to drive
economies of scale• Dragline operations
– Locked coal pillar extraction without surface rights
20 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
OUR THOUGHTS …
• EQUIPMENT PROCUREMENT– Reduce tender periods
• Bonafide and proven suppliers
– DPRs• Outsourcing tenders to have minimum adherence to DPR
recommended equipment packages• DPRs need to be revisited for incorporation of latest technologies,
newer equipment classes / upgrades– Review recommended during equipment replacements in existing
projects– Safety, Enabling better compliance with environment norms
– Adoption of international standards, reduce in-country testing & certification for UG equipment
21 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
OUR THOUGHTS …
• EQUIPMENT PROCUREMENT– Equipment survey off norms to be increased
• Helps planning during equipment replacements• Allows for economic machine rebuild lives in line with global
standards• Lowers owning cost exposure
– Alliances by projects• Package purchases, reduction in no. of suppliers, tenders and
purchase time
– Incorporation of clauses to reward suppliers exceeding conditions of
• Guaranteed availability, Higher utilisation hours, longer survey off life, wider established product support infrastructure, globally accepted technological features, etc
22 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
• OTHERS– Use of OB (crushed) in road building, construction activities
• Revenue generation, saving dumping space
– Feasibility of long distance belt conveyors from mine to end user or coal loading sidings
OUR THOUGHTS …
23 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
© 2013 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, their respective logos,
“Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product
identity used herein, are trademarks of Caterpillar and may not be used without permission.
®
24 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
PRODUCTION/ PRODUCTIVITY ENHANCING FEATURES
• Various bucket and boom options on draglines
• Tri-Power structure on Hydraulic Mining Face Shovels– Faster cycle times, more breakout force
• Custom bodies on trucks to maximise payload
• Autonomous operation feature for dozers for safe use on berm edges
• Safety … Our vision - Safely Home. Everyone. Everyday– Machine design safety– Personal protection
•