Maintenance & Repair Costs - Jones

7/28/2019 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

O Sit S t


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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


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


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



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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



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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




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Crane & Fuel Truck

Crane Usage

Vital in machine build

Component Changeouts

Dump Bodies


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



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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


Technical Support

Warranty

Financial Management

Business System

Rebuild Logistics

Inventory Management

Safety

HR & Payroll

Logistics

Management Tree

Training

Staff RecruitmentStaff vs Machines


Crane Availability


Components vs Machines

Component Planning

Utilization vs. Maintenance

Component Life

Operation Severity

Documents

Maintenance & Repair Costs - Jones