Page 1 I ntroduction WHO: WAMS are a dedicated materials handling service provider creating best...

IIntroductionntroduction

WHO: WAMS are a dedicated materials handling service provider creating best practice by delivering our clients safety benefits, productivity gains and reduced costs through ‘outside the box thinking’, innovative design options and availability & maintainability focus.

Halve the costs – Double the life! - Ask us how

WHERE are we now & WHAT do we want to achieve:We concentrate our efforts on the continual Process of Improvement. By working together with our clients to understand their overall maintenance requirements we offer pro-active improvement by delivering;

Availability

Innovation

Maintainability

HOW do we get there:Incorporate a full service package which includes detailed application analyses, innovative design and engineering, through to recommendation, supply and installation. Followed up with a comprehensive condition monitoring and continuous improvement program.

WHY:Our extensive processes and systems offer;

Predictive maintenanceImproved safety through innovative designReduced inventoryCost reductionsIncreasing plant availability… to name just a few.

WHO: WAMS are a dedicated materials handling service provider creating best practice by delivering our clients safety benefits, productivity gains and reduced costs through ‘outside the box thinking’, innovative design options and availability & maintainability focus.

Halve the costs – Double the life! - Ask us how

WHERE are we now & WHAT do we want to achieve:We concentrate our efforts on the continual Process of Improvement. By working together with our clients to understand their overall maintenance requirements we offer pro-active improvement by delivering;

Availability

Innovation

Maintainability

HOW do we get there:Incorporate a full service package which includes detailed application analyses, innovative design and engineering, through to recommendation, supply and installation. Followed up with a comprehensive condition monitoring and continuous improvement program.

WHY:Our extensive processes and systems offer;

Predictive maintenanceImproved safety through innovative designReduced inventoryCost reductionsIncreasing plant availability… to name just a few.

The The PProcess & the rocess & the SSystem – ystem – POI POI & & WMSWMS

WAMS have developed a regimented “Process Of Improvement” that identifies and details transfer maintenance issues or problems.

This detail is then comprehensively reviewed and used to form the basis of an agreed improvement program (POI).

An online “Wear Management System” (WMS) provides the tools to monitor performance and ensure compliance to the program.

The following pages outline this “Process” (POI) and the “System” (WMS).

WAMS have developed a regimented “Process Of Improvement” that identifies and details transfer maintenance issues or problems.

This detail is then comprehensively reviewed and used to form the basis of an agreed improvement program (POI).

An online “Wear Management System” (WMS) provides the tools to monitor performance and ensure compliance to the program.

The following pages outline this “Process” (POI) and the “System” (WMS).

PProcess rocess OOf f IImprovement - mprovement - POIPOI

Audit & Application AnalysisPerformance BenchmarkingProduct & Design OptionsEngineering Detailed DraftingSupply Management

The “POI” (Process Of Improvement) incorporates the following:

POI POI – Audit & Application Analysis– Audit & Application Analysis

A comprehensive inspection and review of each area is conducted and documented to identify any problems and to provide detailed recommendations for improvement.

A comprehensive inspection and review of each area is conducted and documented to identify any problems and to provide detailed recommendations for improvement.

POI POI – Performance Benchmarking– Performance Benchmarking

WAMS establish strict performance requirements for all our products, against which the results are measured. By establishing benchmarks and monitoring the outcomes, we can identify and implement short and long term performance improvements.

WAMS establish strict performance requirements for all our products, against which the results are measured. By establishing benchmarks and monitoring the outcomes, we can identify and implement short and long term performance improvements.

POI POI – Product & Design Options– Product & Design Options

Innovative Access Solutions Improve;SafetyAvailabilityMaintainability

Innovative Access Solutions Improve;SafetyAvailabilityMaintainability

Material AND design options can be considered because WAMS are not commodity suppliers.

Application specific solutions are tailored to suit the improvement requirements not just available products or materials.

Material AND design options can be considered because WAMS are not commodity suppliers.

Application specific solutions are tailored to suit the improvement requirements not just available products or materials.

POI POI – Engineering– Engineering

3D Modelling is utilised for components and structural designs. This enables us to conduct detailed fit analysis to ensure the product fits first time, every time!

3D Modelling is utilised for components and structural designs. This enables us to conduct detailed fit analysis to ensure the product fits first time, every time!

Complex analysis such as “Finite Element Analysis” (FEA) is carried out where required.

Complex analysis such as “Finite Element Analysis” (FEA) is carried out where required.

POI POI – Detail Drafting– Detail Drafting

Detailed arrangements and manufacturing drawings are produced once design concepts are finalised.

Detailed arrangements and manufacturing drawings are produced once design concepts are finalised.

POI POI – Supply Management– Supply Management

To maximise cost reductions and reduce inventory levels, we can assist in establishing a supply management system that administers everything from product manufacturing and procurement to stock replacement, Just In Time (JIT) delivery scheduling and “Min \ Max” stocking levels.

To maximise cost reductions and reduce inventory levels, we can assist in establishing a supply management system that administers everything from product manufacturing and procurement to stock replacement, Just In Time (JIT) delivery scheduling and “Min \ Max” stocking levels.

WWear ear MManagement anagement SSystem - ystem - WMSWMS

The WMS incorporates the following;

Data Collection (inspections)

Data Input (measurements & tonnes)

Area Status (live, online access)

Area Reporting (reports & action plans)

Performance Summary

WMS WMS – Data Collection– Data Collection

Accurate ultrasonic thickness testing (NDT)Accurate ultrasonic thickness testing (NDT)

Customised measure sheets used for data collection ensure critical measure points are collected at each inspection interval.

Customised measure sheets used for data collection ensure critical measure points are collected at each inspection interval.

WMS WMS – Data Input– Data Input

The WMS allows input of measurement date, Inspection photographs, measurement sheets and thickness values.

Other details such as tonnes or hours can also be collected

The WMS allows input of measurement date, Inspection photographs, measurement sheets and thickness values.

Other details such as tonnes or hours can also be collected

WMS WMS – Area Status– Area Status

The WMS incorporates graphical representations of “wear status” for each zone of the area being monitored.

Being LIVE DATA, this graphic display changes EVERY DAY, so planners always know the condition of their equipment.

The WMS incorporates graphical representations of “wear status” for each zone of the area being monitored.

Being LIVE DATA, this graphic display changes EVERY DAY, so planners always know the condition of their equipment.

WMS WMS – Area Reporting– Area Reporting

The WMS also produces detailed reports which include the parts and costs to be replaced for the report period, as well as photographs and measure sheets from the last inspection.

Customized reports are available on request

The WMS also produces detailed reports which include the parts and costs to be replaced for the report period, as well as photographs and measure sheets from the last inspection.

Customized reports are available on request

WMS WMS – Performance Summary– Performance Summary

WAMSWAMS – Case Studies – Case Studies

SAFETY – Ridgeway impact plates

WEAR – Northparkes Hoisting Skips

FLOW – Ridgeway Picking \ Trunk Chute

ACCESS – Paraburdoo CV-07

AVAILABILITY – BHPB Newman CV216 –CV218

MAINTAINABILITY – Paraburdoo “CV-06” Tripper

The WAMS philosophy is not just about wear but encompasses all

aspects of materials handling improvement.

SAFETY SAFETY – Case Study, Ridgeway “Impact Plates”– Case Study, Ridgeway “Impact Plates”

BEFORE AFTER Material POI $

FreqPOI %

Maintenance Frequency

Material (Only)

Costs $

Projected Cost PA $


Material (Only) Costs $

Projected Cost PA $

2 WEEK 3,930 $102,180 7 WEEKS $ 1,850 $ 13,743 $ 88,437 350%

Before:

A20mm Q&T with 50 & 75mm cast liner system was the original installation

Issues:

High maintenance activity

Inefficient & unsafe rebuild access

High wear rate

Before:

A20mm Q&T with 50 & 75mm cast liner system was the original installation

Issues:


Inefficient & unsafe rebuild access

High wear rate

After:

Designed rotatable liners, Installed rubber compression blocks, Changed cast material specifications, Designed mobile maintenance stand

Benefits:

Reduced maintenance frequency, Safe rebuild access & storage, Availability improvement

After:

Designed rotatable liners, Installed rubber compression blocks, Changed cast material specifications, Designed mobile maintenance stand

Benefits:

Reduced maintenance frequency, Safe rebuild access & storage, Availability improvement

WEAR WEAR – Case Study, Northparkes “Hoisting Skips”– Case Study, Northparkes “Hoisting Skips”


FreqPOI%


Material (Only) Costs

$

Projected Cost PA $ Maintenance Frequency


$

Projected Cost PA $

5 WEEK $45,500 $473,200 16 WEEKS $40,000 $ 132,000 $ 343,200.00 320%

Before:50 to 180mm rubber

Issues:


Reduced volume capacity

Before:50 to 180mm rubber

Issues:


Reduced volume capacity

After:20 to 32mm tapered cast lining system incorporating saw tooth60mm impact zone with 16mm Q & T steel sides & roof

Benefits:

Reduced maintenance frequency

IMPROVED wear material distribution

After:20 to 32mm tapered cast lining system incorporating saw tooth60mm impact zone with 16mm Q & T steel sides & roof

Benefits:


IMPROVED wear material distribution

FLOW FLOW – Case Study, Ridgeway “Picking Spoon”– Case Study, Ridgeway “Picking Spoon”


FreqPOI %



$

Projected Cost PA $ Maintenance Frequency

Material (Only)

Costs $

Projected Cost PA $

1 WEEK $ 2,000.00 $ 104,000.00 7 WEEKS $ 8,000.00 $ 59,000.00 $ 45,000.00 700%

Before:

50 & 75mm Q&T liner strips and discharge ledge liners

Issues:


Restricted material flow (rockboxing)

Before:

50 & 75mm Q&T liner strips and discharge ledge liners

Issues:


Restricted material flow (rockboxing)

After:

50mm Cast lining incorporating corners on curved back wall.

Side walls & skirts are standard tiles

Benefits:


Improved material flow

After:

50mm Cast lining incorporating corners on curved back wall.

Side walls & skirts are standard tiles

Benefits:


Improved material flow

ACCESS ACCESS – Case Study, Paraburdoo “CV-07”– Case Study, Paraburdoo “CV-07”

Before:

Fixed steel skirt plates (no adjustment)

Cumbersome dust sealing system

Issues:

Poor maintenance access

Safety issues (confined space), significant risk of manual handling injuries

Down line affect – Belt damage

Before:

Fixed steel skirt plates (no adjustment)

Cumbersome dust sealing system

Issues:

Poor maintenance access

Safety issues (confined space), significant risk of manual handling injuries

Down line affect – Belt damage

After:

Design and install a modular skirting system that can be fully maintained externally (eliminating confined space entry requirements)

Reducing risk of manual handling injuries associated with liner and skirt seal replacement.

Design and install UHMWPE primary and rubber secondary skirt seals to improve sealing

Benefits:

Full external access

Simplified skirt clamping mechanism

Quick liner replacement

After:

Design and install a modular skirting system that can be fully maintained externally (eliminating confined space entry requirements)

Reducing risk of manual handling injuries associated with liner and skirt seal replacement.

Design and install UHMWPE primary and rubber secondary skirt seals to improve sealing

Benefits:

Full external access

Simplified skirt clamping mechanism

Quick liner replacement

AVAILABILITYAVAILABILITY – Case Study, BHPB Newman– Case Study, BHPB Newman“CV216 to CV218” Transfer“CV216 to CV218” Transfer

After:

Installed WAMS “Liner Less” chute system

Benefits:

Liner wear almost eliminated

Shutdown regime extended to 8 weeks (plant requirement not chute related)

Chute “blowouts” eliminated

After:

Installed WAMS “Liner Less” chute system

Benefits:

Liner wear almost eliminated

Shutdown regime extended to 8 weeks (plant requirement not chute related)

Chute “blowouts” eliminated

Before:

“Hood and Spoon” composite white iron block lined chute system

Issues:

Severe liner wear

4 week inspection/repair regime

Regular chute “blowouts”

Before:

“Hood and Spoon” composite white iron block lined chute system

Issues:

Severe liner wear

4 week inspection/repair regime

Regular chute “blowouts”

MAINTAINABILITY MAINTAINABILITY – Case Study, – Case Study, Paraburdoo “CV-06” TripperParaburdoo “CV-06” Tripper

After:

Installed WAMS patented “Gridlock” liner design

Benefits:

Joint wash significantly reduced (almost eliminated)

Improved liner utilisation

Consistency in liner wear (accurate change out forecasting)

After:

Installed WAMS patented “Gridlock” liner design

Benefits:

Joint wash significantly reduced (almost eliminated)

Improved liner utilisation

Consistency in liner wear (accurate change out forecasting)

Before:

Traditional brick pattern liner system using rubber backed white iron liners

Issues:

Severe liner joint wash

Poor liner utilisation

Irregular liner change outs (individual liner cracking requiring replacement, difficult to forecast change outs)

Before:

Traditional brick pattern liner system using rubber backed white iron liners

Issues:

Severe liner joint wash

Poor liner utilisation

Irregular liner change outs (individual liner cracking requiring replacement, difficult to forecast change outs)

WAMS WAMS – Supporting documents– Supporting documents

WAMS standard products list

WAMS WAMS – Operational Areas– Operational Areas

Olympic DamOlympic Dam

DampierDampier

MIMMIM

TelferTelfer

LihirLihir

OsbourneOsbourne

EndeavourEndeavour

PeakPeak

ParaburdooParaburdoo

TrittonTritton

Lake CowalLake Cowal

CADIACADIA

Cape LambertCape Lambert

LeinsterLeinster

NorthparkesNorthparkes

ChannerChanner

West AngelesWest Angeles

WAMS Perth OfficeWAMS Perth Office

Orange \ Parkes OfficesOrange \ Parkes Offices

Newcastle OfficeNewcastle Office

Rio Tinto (OTX), BHPB (MP)

Rio Tinto (OTX), BHPB (MP)

For WAMS contact details please click on the “Web” link above & then click “Contact Us”.For WAMS contact details please click on the “Web” link above & then click “Contact Us”.

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