Asset Maintenance Management in Coal Mining

Summary-document-Zibulo-026-Part1.pptx

• Why Emphasis on MM

• Overview of Maintenance History

• Asset Maintenance Management Approach

• Maintenance tactics

• Defect elimination

• Work management

• Influencing the fife cycle curve

• Equipment risk

• Driving reliability from a divisional centre

• My experience of practical implementation

• Challenges

• Questions

Contents

3

Improving Cost Performance

• Improved Labour

Utilisation

• Overtime reduction

• Scheduled vs.

Unscheduled Costs

Reducing Risk

• Planned Work is Safe

Work

• Statutory compliance

peace of mind

• Reduction of Value @

Risk

• ISO 55 000

Improving Asset Performance

• Improved equipment

reliability

• Improved equipment

availability

• Increased productivity

• Defect Elimination

Why Emphasis on Maintenance Management?

Engineer FocusArtisan Skill Level

• Safety Has taken off

• Environment

• Asset optimisation

• Community

• Standard groups

• Supply Chain

• Maintenance

• Scarce

• Skill level decreased

• Attractions abroad

• Passion lacking

• Maintenance plan 1980

vs. Maintenance plan

now

• Age Distribution

Things have changed

Maintenance System and Plan to Support the Changes

Overview of AATC Maintenance History

5

1993-1994

• MIMS ERP Introduced

• All disciplines (Maintenance Priority)

• Practices driven by ERP Requirements

• Ad-hoc Pragma Involvement

• Operations implement own practices

2004

• First Formal Maintenance Strategy

• Based on Best Practices

• Maintenance Temple Introduced

2010-2013

• Central Maintenance Management

• Guidelines Developed

• Self Assessment

• AATC Policy and Stated Objective

• Reliability Engineers & MCO’s

1976

• Peg Board Scheduling

Introduced

• Availability a Manual KPI

1983

• Start Maintenance

Planning Committee

• Planning Standards

developed

1984

• Computers

Introduced

• Basic KPI’s

1987

• 1st CMS: Promain (In-House)

• Subs, Scheduling, KPI’s (No

Work Orders)

• Not linked to finance or stores

2009

• AA develop OAAM Framework loosely

based on Pragma AmiP

• AATC (NVC) Contribution

• New Maintenance Temple Developed

6

Asset Maintenance Management• 11 Elements

• Maturity Model for each

• Set of Best Practices captured in a Guideline

• Tools for On-site Implementation

• Training Support at AATC Learning & Development

• Supported from Centre with Champions at each Site

Implementation

Measurement

Standards &

Governance

7

• MM Best Practice

• ERP Utilisation & Reporting

• Equipment & Ops performance

• MM Maturity & Systems

• Co-ordination of effort

• Provide training / Coaching –

On site / Forums /L&D

Principle

Reliability

Engineer

Systems Co-

Ordinator

(ERP)

Pragma

(Ad-Hoc Training

& Imlementation)

Learning &

Development

IM

(Engineering

Related)

Reliability

Engineer

Section

Engineer

Section

Engineer

GES /

Foreman

Engineering

Planning

Condition

Monitoring

Engineering

Manager

Technical

Expediting

GES /

Foreman

MCO MCO

Site

Maintenance

Structures

informed by:

Size of the operation and

equipment deployed

Affordability

Ability to share / Geography

Moving Towards a Best Practice Maintenance Structure

Translating Theory into Practice

Our Challenge…….

8

Equipment Register Maintenance Tactics

• Must be right and up to

date

• Method adding equipment

• Criticality analysis

• Performance

requirements

• Disciplined information

capture

Start with the Maintenance Plan

• Process of identifying how you want your resources

to perform certain tasks aimed at preventing failures

• Process in identifying preventative tactics focussed

on criticality analysis of equipment

• Process of identifying critical spares based on risk to

the business unit

• Maintenance Plan that an artisan believes in

Maintenance Tactics

10

Equipment:

List the Primary Function of the Equipment:

List the Seconday Functions of the Equipment:

(If Any)

List all Relevant Performance Requirements: Eng Availability:

(Add / Amend list as required) Eng Reliability (MTBF):

MTTR:

Speed:

Load:

Max Gradient:

R/hour:

Performance RequirementsICV001 SF CONVEYOR 1 - INCLINE CA L

SCP005 SF COMPRESSOR 5 (CRUSHER SUB) ATLAS COPCO / LFX / K09/423 CC L K09/423

SCP006 SF COMPRESSOR 6 (CRUSHER SUB) ATLAS COPCO / LFX / F09/237 CC L F09/237

SCP007 SF COMPRESSOR 7 (SHAFT/WINDER SUB) ATLAS COPCO / GA11+ / APIS44045202 CC L APIS44045202

SCP008 SF COMPRESSOR 8 (SHAFT/WINDER SUB) ATLAS COPCO / GA11+ / APIS44045201 CC L APIS44045201

SCP009 SF COMPRESSOR 9 (SCV003 CRUSHERS) ATLAS COPCO / GX2+ / CAI363236 CC L CAI363236

SCR001 SF PLANT CRUSHER 1 - PRIMARY CA L

SCR002 SF PLANT CRUSHER 2 - SECONDARY CA L

SCV002 SF CONVEYOR 2 - CLEARANCE CA L

SCV003 SF CONVEYOR 3 - ACCELERATOR CA L

SCV004 SF CONVEYOR 4 - OVERLAND CA L

SDS001 SF STONE SILO 1 CB L

A B C Safety Cost of Repair Production Impact

Dam wall - - 13 5 3 5 1

Dam Pipes - - 7 2 2 3 1

Dam Level Monitor - - 12 1 1 1 4

Pump - - 10 1 3 1 2

Assembly / ComponentComponent Criticality

Criticality Analysis

Failure Consequence Probability

Equipment:

Location:

Assembly /

ComponentCriticality

Primary and

Secondary FunctionFailure Description Root Causes Warning Effect Maintenance Tactic

Statutory

Requirements /

Considerations

Task descriptionThreshold

Value

Interval

Frequency

Task

Duration

(Hours)

Trade AllocationRunning /

StationaryVibration

Oil

AnalysisWear Thermo Spare

Lead

Time

Where Should it

be kept?

Special Tools

Required

Walls C Retaining water Erupts,cracks Excess pressure, poor installtion,

incorrect protection devices

Leaks Condition Based MHSA reg 10.2 Physical Inspection 3 Monthly 0.5 hr Running

Check for any cracks 5 mins Fitter

Check for any wet paches 5 mins Fitter

Check the sides and floor for any seepage 5 mins Fitter

Check for any concrete corrosion 5 mins Fitter

Check for any structural damage 5 mins Fitter

Check for any concrete wear 5 mins Fitter

Check integrity of side walls 5 mins Fitter

Check for any chemical damage to the concrete 10 mins Fitter

Check integrity of viewing platforms 10 mins Fitter

Assembly

Underground Dam

Underground - Shaft Area

FMEA Tactic Selection Special Tools

AATC Maintenance Tactics

Condition MonitoringTask Detail Spares analysis

Defect Elimination

11

Defect Elimination

10 Hours of DE Work

R 4.2 Million Revenue

Saved p.a.

Taking to the Artisans….. Regularly

• Technical discussion defect elimination

• Maintenance discussion MM framework

• In house training on specific item on downtime that repeats

• Shell, bearing man presenting on basics

• The artisans cannot get enough.

• Feel engaged• Contribution heard• Immediate buy in• Results felt

Defect Elimination

Work Management

14

Work Management

15

Formal meeting with

Correct audience

Meeting must be prepared for

Work allocated involved std work

Follow up work and condition monitoring

Closing loop: Improve maintenance plan from feedback

Over inspect work

Identify further opportunities for improvement

16

Influencing the Life Cycle CurveEQUIPMENT DESCRIPTION 2013 YTD 2014 2015 2016 2017 2018 2019 2020

CONTINUOUS MINER - SECTION 1 3.4 5.1CONTINUOUS MINER - SECTION 2 1.7 4.3CONTINUOUS MINER - SECTION 3 1.7 4.3CONTINUOUS MINER - SECTION 4 2.6 4.4CONTINUOUS MINER - SECTION 5 3.1 4.75CONTINUOUS MINER - SECTION 6 2.4 5.6CONTINUOUS MINER - SECTION 7 3.4 6CONTINUOUS MINER - SECTION 8 1.8 4.75

REPLPACEMENTOVERHAUL

MAJOR SERVICE

CurrentTons/Life Expected Life Change out Strategy Comments

Cutterboom 1508975 2.5 Mt Next intervention Weld cracks continiously

Cutter Gearcase 1508975 1.8 Mt Order one 2014 300 000 Tons left 9 months,signs of

secondary gear wear

Drums 1383767 1Mt Done Changed

Cat tracks 990 617 Condition based 2014 Q 1 Tension

Liners 1508975 2.5 Next intervention Small cracks, weld

Conveyor Boom 1508975 2.5 Mt Change condition based, monitor

cracks. Stabilizing shoes important

ASAP, single drive spare

available

Roof plates to be ordered. We have to

change the boom small cracks on

clevisses and extensive sagging

Flight Chain 1383767 1.5 Mt Order ASAP If tensioned coorectly can still reach

expected life.Order one immediately to

have it time

Spade 1508975 1.8 Mt Order Q2 2014 Spare swing spade available

Pots 1508975 1.5 Mt Order Q2 2014 Pay close attention to condition

LH Planetary 14200 800 000 Per conmon Drain and flush bi weekly , Discuss with

Derik and Joy

RH Planetary 1 269 272 800 000

Pins and Bushes Worn 2.5 Mt Plan it weekend for weekend Has to be greased daily

Motor Cutter LH 205876 1.5 Mt

Motor Cutter RH 202220 1.5 Mt

Cylinder Shear LH 42841 1.2 Mt

Cylinder Shear RH 771490 1.2 Mt

0

200000

400000

600000

800000

1000000

1200000

1400000

1600000

CM 1 CM 3 CM 4 CM 5 CM 6 CM 7 CM 8 AVE

2014 current PLanetary Life

LH

RH

0

200000

400000

600000

800000

1000000

1200000

1400000

1600000

1800000

CM 1 CM 3 CM 4 CM 5 CM 6 CM 7 CM 8

Cutter gearcase tons

Life Cycle Management

CONTINIOUS

MINERS 275

SHUTTLE CARS

54

BATTERY HAULERS

222

FEEDER BREAKER

S5

-To enable your business to plan major

subs/rotables in a controlled

environment

-Tracking subs/rotables & comparing

-Separating performers from failures

-DFE

Equipment Risk

Best Practice Sharing Across Operations

19Maintenance

Newsflashes

Best Practice

Coach Material

Maintenance VideoDefect Elimination

(RCA Findings)

Eureka! Space

Maintenance Org Forums

Site Implementation Packages

Driving Reliability from a Divisional Centre

Engineering Planning User GroupTwo Monthly

Strategic Thrusts

• Ellipse and MM Training

• Reducing need for Ellipse business support

• Standardisation of ERP Utilization

• Governance and Standardisation

Equipment

Register

Project

Control

Equipment

Group

Identifier

Maintenance

Scheduling

Work

Orders

Drawing

Index

Correspondence

Index

Equipment

Tracing

Equipment

Costing

Fuel & Oil

Issues

Condition

Monitoring

APL’s Standard Jobs

Labour Costing

Operating

and

Prod Stats

Condition Monitoring ForumMonthly

Strategic Thrusts

• Fuel and Lubrication Standards

• OEM / Contractor Con Mon

• Standardise Con Mon Programmes

• Best practice sharing

• New Technology – Test & Learn

20

Maintenance ForumsMCO Forum & AcademyMonthly and L&D

Strategic Thrusts

• Clarifying Role Profile

• Sharing of Best Practice & DE

• Improve and certify competency

Driving Reliability from a Divisional Centre

21

Operation Training

Buy - in Contractor management

CHALLENGES

Skill level

Acceptance to change

Tension maintenance

time/cost vs. productivity

Maintenance plan vs. actual

Asset management driven

from senior level

Implementation demand

Succession planning

Bridging the gap

Skill not out there

Frontline understanding

MARC/LCC/CPT

Aligning contractors to

our plan

Contract

Current Coal Experience

Level of effort

Re

sult

Questions