Komatsu 7th GTI
Reduce Down Time on 930E fleet in AJL coal
mine
Li Guohui Komatsu (China) Mining Ltd. Product Spport Section Service Department 2012-3-2
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Agenda
1 、 Background of AJL Coal Mine2 、 Introduction of Komatsu (China) Mining Ltd3 、 Availability review of 32 x930E fleet4 、 Machine down time analysis and action ( GENBA )5 、 Future action plan
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1 、 Background of AJL Coal Mine
China coal is one of biggest customer for KCML.KCMLhave been committed to the customer first.Support the customer and keep Komatsu machine high availability.So how to reduce machine downtime is very improtant and urgent!
ATB Coal Mine
East Coal Mine
AJL Coal Mine
China Coal Ping Shuo Coal Co.Ltd.
Komatsu 7th GTI2 、 Introduction of Komatsu (China) Mining Ltd. /(KCML)
Established: Sept.2010Total SS, 8 and Staff, 93Average experiece:1.98 yrs.Machine population:595 units - 332 Dump trucks - 263 Construction machines
Established: Sept.2010Total SS, 8 and Staff, 93Average experiece:1.98 yrs.Machine population:595 units - 332 Dump trucks - 263 Construction machines
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ShengLi SSDatang SSM/P:51
Zhungeer SS
M/P:135
Pingshuo SS
M/P:262
Dexing SSM/P:61
Baotou SSM/P:12
Huolinhe SS
M/P:58
Beijing HQ
Chengmshan SS
M/P:12
KCRC 44PRebuild Center
Parts warehous
e
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2-1 、 Organization Chart of KCML Product Support Div.
Customer support and SS supportQuality control and operation Service system operation
Customer support and SS supportQuality control and operation Service system operation
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3 、 Availability of 32 x930E in AJL for the period of Jan. 2011 to Dec. 2011
Year
Warranty condtion
Fleet avaibility target
Unit avaibility target
1Standard warranty
92% 90%
2Extended warranty
90% 88%
3KCML(Target)
88% 85%
32 units 930E’s Contract Availability Review (the last unit delivered in Dec.2009 )
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4 、 Machine Down Time Analysis Through KCML Monthly Report
Engine is the biggest factor of downtime
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4-1 、 What is the problem on the engine and Why? Identify potential root causes for engine down time using fishbone diagram ( draft)- hypothesis
QualityTool & facility
Repair
Parts Operator Maintena
nce
Cold start
Sudden stop
Local parts
Parts error
Lack of facility
Experience
Speed control
Lack of inspection tools
No standby and stock
Accident Lead
timeOil
Coolant
Environment
Not On time
Air
Manpower
Assemble
FC issue
Design
Material
Management
Troubleshooting
No place
Lack of tester
Engine breakdown
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4-2 、 Engine Down Time Analysis(Jan.2011-Jul.2011)
CustomerNo.of Dump Truck
Customer CEBJ / Cummins
TotalNew
Rebuilt
Under OV On Ship New Rebuilt Under OV On Ship
PingShuo (ATB/AJL/East mine)
90 2 16 2 2 - 3 25
Standby engine situation as of Jan.2012
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4-3 、 Engine Down Time Analysis(Aug.2011-Dec.2011) 1 、 The engines
have to overhaul based on machine operate hours ( 20000 Hours ) .2 、 What are the root causes for the long time needed for the engine to be removed and re- installed with standby engine?
Unschedule overhaul Schedule overhaul
Unschedule overhaul Schedule overhaul
8 units engine need to remove and reinstall
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4-4 、 Engine Replacement Process (GENBA) /Root Cause Analysis And ActionMachine 930E/A30598 Failiure date:2011-12-8Operating hour
19388
Subject Reason for engine overhaul: Metal chip found in oil pan and high SMR close to 20,000 hours.
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No. Finding
Process No.
Root Reason ActionResponsi
ble
Schedule
Aug
Sep
OctNov
Dec
JanFeb
Mar
1 Awaiting for engine mount
④ Lack of engine mount in jobsite
Increase one set engine mount by Cummins
Cummins Customer
●
2
Remove and re- install is longer
③⑤⑥ Unclear responsibility and lack of positivity
One face meeting to clarify responsibility and prevent process delay
Customer Cummins KCML
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● ○ ○
50% of Downtime can be Reduced
-24 -70 -6-12
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4-5 、 Machine Troubleshooting Process (GENBA) Root Cause Analysis And ActionMachine 930E/A30653 Failure date: 2011-8-24Operate hour
15500
Subject Engine with abnormal noise, LH #4 air valve drop off and damaged and cylinder head damaged
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③ ④ ⑥ ⑦⑤②① ⑧-24 -24 -46 -14-54 58% of
Downtime can be reduced
No. Finding
Process No
Root Reason
Action Responsible
Schedule
Aug
Sep
OctNov
Dec
JanFeb
Mar
1 Awaiting for related equipment
⑤⑦ No plan for repair job
Make plan and prepared equipment in the advance
Cummins Customer
● ●
○ ○
2
Troubleshooting and remove &intall is longer
②③⑥
Lack of positivity and experience
To clarify responsibility by monthly meeting and special training
Customer Cummins KCML
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●
● ● ○
Provide 2 sets of INSITE software
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4-6 、 Appendix
According as customer experience and knowledge Remove and install Reasonable hours in AJLcoal mine:84Hours
Item (Productivity ) #1 -930E/A30598 #2 -930E/A30653Actual downtime Hours
225 278
Reasonable downtime Hours
113 116
Unreasonable hours 225-113=112 278-116=162Trip/Hours 3 3Production loss (Tone)
290x3x112/1.8x6=9,022T 290x3x162/1.8x6=13,050T
Average Profit Ton USD/T
12.3 (2011Y) 12.3 (2011Y)
Profit loss(Estimation)
110,970 USD 160,515 USD
4-6-2 、 Estimated profit loss from machine Downtimes
Note:Density/1.8Coal:OB/1:6Exchange rate/1:6.4
4-6-1 、 Standard Labor Hours From Cummins
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5 、 Future Action Plan In order to ensure the 930Ex 32 units fleet availability of more than 90% and keeping a good relationship with Customer to increase the customer satisfaction the following activities are needed and will be monitored.
No Action Purpose Responsible Schedule
1
Weekly comunication and planning with customer‘s maintenance management
Understanding Job task •Site Mgr.•Planner•Cummins
Every week from Jan.2012
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Provide each Machine inspection data to customer, Understanding machine status
identify problems and recommend to prepare the related equipment for optimization of the facilities.
•Planner•Cummins•Customer
Every month from Mar.2012
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Provide customer with the machine downtime report for improvement to minimize down time.
Identify problems and improvement through case study
•Planner&Mgr.•Customer•Cummins
Anytime
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Komatsu ICT system(EQP 、 Web care etc.) support to customer
Forecasting and reduce down time and shorten parts lead time
•KCML Service Dep.•Planner
Anytime
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Appendix
1 、 Improvement point by KCRC Support2 、 China Coal 930E Engine OV Plan / Progress3 、 Mechanical & maintance training by Cummins4 、 Improvement point by Care Project 5 、 Planner
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1 、 Improvement point by KCRC Support
Front view
Disassemble
Inspection
Assemble Testing
KCRC Expansion Project
Reduce 930E Down Time & Operating Cost,to schedule OV and Reduce unschedule failure AJL:1> 、 Alternator2> 、 Wheel motor/7units3> 、 Suspension
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2009
Result2010-2011/7
Result
2011 Plan 2012 Plan
Aug Sep Oct Nov Dec Jan Feb Mar
CEBJ OV Capacity ( PS) - - 6 8 8 8 8 8 8 8
No. of Swing Eng.Ready for Use
- - 4 4 4 4 4 4 4 4
OV Plan (20000h) - 0 3 3 3 4 4 4 4 4
No. of OV executed
(AJL)
Scheduled OV 0 0 0 0 1 0 3 Unscheduled OV 0 7 0 0 3 1 4 0 Total 0 7 0 0 3 2 4 3 0 0
Truck Chasis Latest SMR Latest DateOriginal
ESN1st COSMR
1st CODate
Sch/Usch
2ndESN
EstimatedEngine Hrs As of Today
Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12
9341 A30533 10,800 2011-05-31 33168354 10,800 10,800 10,800 10,800 10,800 10,800 10,800 10,800 10,8009342 A30580 11,549 2011-05-31 33168349 11,549 11,549 11,549 11,549 11,549 11,549 11,549 11,549 11,5499343 A30617 11,545 2011-05-31 33168352 11,545 11,545 11,545 11,545 11,545 11,545 11,545 11,545 11,5459344 A30645 12,407 2011-05-31 33171794 11,019 2011-03-12 Usch 33167575 1,388 1,388 1,388 1,388 1,388 1,388 1,388 1,388 1,3889345 A30646 14,754 2011-05-31 33171820 14,754 14,754 14,754 14,754 14,754 14,754 14,754 14,754 14,7549346 A30649 14,318 2011-05-31 33171823 14,318 14,318 14,318 14,318 14,318 14,318 14,318 14,318 14,3189347 A30653 13,736 2011-05-31 33171980 5,957 2010-04-20 Usch 33169971 7,779 7,779 7,779 7,779 7,779 7,779 7,779 7,779 7,7799348 A30656 14,731 2011-05-31 33172036 14,731 14,731 14,731 14,731 14,731 14,731 14,731 14,731 14,7319349 A30597 15,965 2011-05-31 33170286 15,965 15,965 15,965 15,965 15,965 15,965 15,965 15,965 15,9659350 A30612 14,182 2011-05-31 33170711 14,182 14,182 14,182 14,182 14,182 14,182 14,182 14,182 14,1829351 A30616 15,111 2011-05-31 33170999 15,111 15,111 15,111 15,111 15,111 15,111 15,111 15,111 15,1119352 A30619 14,924 2011-05-31 33171157 14,924 14,924 14,924 14,924 14,924 14,924 14,924 14,924 14,9249353 A30622 15,423 2011-05-31 33171288 15,423 15,423 15,423 15,423 15,423 15,423 15,423 15,423 15,4239354 A30624 15,735 2011-05-31 33171612 15,735 15,735 15,735 15,735 15,735 15,735 15,735 15,735 15,7359355 A30640 15,335 2011-05-31 33171608 15,335 15,335 15,335 15,335 15,335 15,335 15,335 15,335 15,3359356 A30642 16,070 2011-05-31 33171627 7,485 2010-01-04 Usch 33173193 8,585 8,585 8,585 8,585 8,585 8,585 8,585 8,585 8,5859357 A30579 17,389 2011-05-31 33170053 17,389 17,389 17,389 17,389 17,389 17,389 17,389 17,389 17,3899358 A30594 17,599 2011-05-31 33170455 17,599 17,599 17,599 17,599 17,599 17,599 17,599 17,599 17,5999359 A30595 16,545 2011-05-31 33170080 12,628 2010-11-13 Usch 33173195 3,917 3,917 3,917 3,917 3,917 3,917 3,917 3,917 3,9179360 A30596 16,200 2011-05-31 33170456 16,200 16,200 16,200 16,200 16,200 16,200 16,200 16,200 16,2009361 A30623 17,618 2011-05-31 33171492 17,618 17,618 17,618 17,618 17,618 17,618 17,618 17,618 17,6189362 A30598 16,570 2011-05-31 33170617 14,133 2011-01-28 Usch 33169019 2,437 2,437 2,437 2,437 2,437 2,437 2,437 2,437 2,4379363 A30610 17,170 2011-05-31 33170615 17,170 17,170 17,170 17,170 17,170 17,170 17,170 17,170 17,1709364 A30611 15,031 2011-05-31 33170661 14,435 2011-04-24 Usch 33164910 596 596 596 596 596 596 596 596 5969365 A30484 17,893 2011-05-31 33166262 17,893 17,893 17,893 17,893 17,893 17,893 17,893 17,893 17,8939366 A30485 17,160 2011-05-31 33165960 16,056 2011-04-01 Usch 33171980 1,104 1,104 1,104 1,104 1,104 1,104 1,104 1,104 1,1049367 A30486 17,722 2011-05-31 33166281 18,994 2011-07-24 Usch 33165980 -1,272 -1,272 -1,272 -1,272 -1,272 -1,272 -1,272 -1,272 -1,2729368 A30487 17,851 2011-05-31 33166181 17,851 17,851 17,851 17,851 17,851 17,851 17,851 17,851 17,8519369 A30490 18,002 2011-05-31 33166095 18,002 18,002 18,002 18,002 18,002 18,002 18,002 18,002 18,0029370 A30491 18,801 2011-05-31 33166844 20,716 2011-09-19 Sch 33167030 -1,915 -1,915 -1,915 -1,915 -1,915 -1,915 -1,915 -1,915 -1,9159371 A30492 17,500 2011-05-31 33166838 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,5009372 A30493 17,938 2011-05-31 33166806 17,938 17,938 17,938 17,938 17,938 17,938 17,938 17,938 17,938
China Coal 930E Engine OV Plan / Progress
Sch OV Plan
Sch OV done
Unsch OV done
2 、 China Coal 930E Engine OV Plan / Progress
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3 、 Mechanical & maintance training by Cummins No Training Date ATB AJL DLT -
Technician
OperatorMid Class Manager
1
Maintenance(A,B,C Check)
Training
Projected Completion Date
20-May-11 21-May-11 22-May-11
Actual Completion Date
21-May-11 21-May-11 21-May-11
2Operation Training
Projected Completion Date
17-Oct-11 17-Oct-11 17-Oct-11
Actual Completion Date
3Coolant Training
Projected Completion Date
20 –May-11
20 May.2011
20 May.2011
Actual Completion
Date20 –May-
1120
May.201120
May.2011
4Oil and Oil Analysis Training
Projected Completion Date
17-Oct-11 17-Oct-11 17-Oct-11
Actual Completion Date
5Insite
Training
Projected Completion Date
18-Oct-11 18-Oct-11 18-Oct-11
Actual Completion Date
6Troubleshooting Onhand
Training
Projected Completion Date
From May to the end of this year, totally eight persons
Actual Completion
Date
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10
20
30
40
50
60
70
80
SMR VHMS Data Downt i me Component OV
Before Now
1 、 AJL Basic information collect unit2 、 Machines down hours analysis3 、 Machines health Monitoring
Before Apr.2011 Now
Machine Downtime
VHMS Data
OV Record
SMR
Only report SMR of warranty machines
Make major failure report of warranty machines
No major component change out record
Monthly report SMR of allOperation machines
Record all downtime data for important model
Follow all major componentChange out history
Lack of operation machines informationNo plan for major component overhaulParts lead time was long
Have more machines operation informationMake major component overhaul forecastingReduce machines down time by scheduledOV and shorten parts lead time
R+M Care EQP Care
Web Care
4 、 Improvement point by Care Project
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Web Care
R+M Care
EQP Care
KOPEN
Initialization and registration of newly delivered machines into KOMTRAX+.
KOMTRAX+ data download and upload to WebCARE. (Daily/Weekly)
Monitor machine health condition and register to Backlog sheet if any abnormalities.
Receive machines downtime information from customer.
Type downtime and usage data up to template sheet and upload to R+Mcare, as well as weekly downtime sheet
Analysis of machine downtime reason using R+M Care and weekly downtime sheet
Obtain machine SMR & major component change-out history from customer.
Report machine SMR & component change-out history to HQ service department
Monitoring & scheduling component OV and advise to SS manager
Registration & management of Backlogs using Backlog Management sheet.
Advise to Parts Key Person to order the necessary parts & component.
Timely open & close work order
Daily
Monthly
Monthly
Daily
To monitor trend data for OV timing optimization
To find and report some abnormalities timely
To forecast major component OV timing
To find machine downtime reasons and take action for improvement
Update SS parts & component stock condition
Report Customer’s parts & component stock condition to HQ parts Dept
Forecast parts consumption in SS
System
Check machine performance timely (Availability/Utilization/ MTBF/MTTR)
Scope of Work Purpose
To prepare adequate parts & component
To complete all the job in timely manner
Control and manage work order in progress
Advise to customer for component OV schedule
Advise to customer for customer’s parts & component stock.
Conduct SS team to do the proactive job for preventing catastrophic failure
SS Manager
Planner
Parts Foreman
Transparency of Stock Condition Suggest to customer
their own parts stockage
5 、 Planner’s “Scope of Work”
To accumulate machines usage for business plan
To order necessary parts for SS timely
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