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EAME Miners Forum Malaga - 2007

Mining expertise, business solutions

Financial Management of Equipment Evaluating Maintenance & Repair Costs

Direct Equipment Costs

Expenditures against equipment as a result of Planned Maintenance, Breakdown or Preventative Maintenance


In-Direct Equipment Costs

Expenditures undertaken to support and facilitate fleet maintenance; on-site & off-site

In-Direct Machine Financial Requirements

On-Site Support
Set Up Costs Tooling Service Vehicles Planning Component Inventory Parts Inventory Losses Consumable Inventory Safety Operation Severity

Off-Site Support
Inventory Management Non Cat Parts Sourcing Continuous Improvement Technical Support Warranty Financial Management Business System Rebuild Logistics

Staffing
Staff Recruitment HR & Payroll Management Tree Logistics Training

Critical Success Factors


Components vs Machines Staff vs Machines Component Planning Early SMU Management Crane Availability Fuel Truck Availability Utilization vs. Maintenance Component Life

On Site Support

Set Up Costs
Mining normally in Remote Location Internet connection
V-SAT Maintenance of communicatiions Computers Laptops Consumable Dispensing Units Lubricant Suction Units Air Lines Demarcation Lines CC & Safety Signage Walk Around PM Stand Kidney Loop Equipment Integration Drip Trays Tooling Cabinets and Tool Boxes Workbenches

On Site IT

Workshop Set Up

PM Bay Set Up

On Site Support

Set up Costs
Oil Dispensing Units
Environmentally complying Cubes Fine in-line filtration Pump Consumables Pressurized Water Supply allowing localized and efficient washing Furniture IT Printers, Scanners etc. Cupboards, cabinets Planning Boards

Wash Bay Facility

Office Facility

On Site Support

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

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

Service Vehicles
Specialised Support Equipment
Telehandlers
Facility Manoeuvrability Component Replacement Man Basket Function Parts and Component Manoeuvrability General Workshop use Component replacement Heavy / Large item transport

Fork Lift

Hiab Truck

Specialised Maintenance Equipment


Welding Bay
Mobile / Stationary Welding Sets Work benches Mobile / Stationary Air supply in field

Compressor

On Site Support

Planning
Storage of WIP (Backlog) Parts
Shelving Plastic Boxes Clipboards Warehouse space Component Planning Boards PM planning Boards Business Dealer System
Capture planning functions

Planning Visual Aids


Information Storage

Machine History Files Storage Room

On Site Support

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 Finance Cost Depreciation Rust Prevention Forklift Access

Charges

Component Space Allocation


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On Site Support

Consumable Inventory & Losses


Lubricant
Grease, Oil & Coolant Finance Costs Logistics

Welding Consumables
Nitrogen & Oxygen Bottles Grinding Discs Welding Rods Rags Contamination Control
Wipes Mats

Workshop Consumables

Stationary
Printed Forms Printer paper and cartridges

Theft Dead Stock Wastage


Oil & Fuel

Incorrectly ordered parts Warranty Claims Poor Workmanship

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On Site Support

Safety
Personal Protective Equipment
Vests Boots Glasses Hats Welding Screens Flashing Lights Buggy Whips ROPS Mounting and Dismounting Standards Lock Out Devices Wheel Chocks Chains Periodic Inspection Crane Inspection and Certification Lifting Training

Vehicle Safety Enhancements


Fleet Safety Enhancements


Lifting Device Certification and Training


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On Site Support

Operation Severity
Operation Severity Measurement
Consistency Key Performance Indicators Long Term Abuse
Transmission Shifting Retarder Control Torque Stall

Operator Influence

Pit Floor / Haulroad Influence


Fleet Life Labour Hour Calculations Workshop Space Calculations Tyre Maintenance Strut Maintenance Body Maintenance Tyre Maintenance

Loading Practices influence


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Off Site Support

Inventory Management & Non Cat Parts Sourcing


Central Inventory Control
Initial inventory stocking Min / Max Setting Re-ordering metrics Parts Clearing In country logistics GET Management
Cost / Hour Hrs / Change CTS Inspections Wear rates Shoe Life Link Life Roller Life Frame Life

Fast Moving Parts

Undercarriage Management

Non CAT Sourcing


Mega Water Truck Spares Service Truck Spares Fork Lift Parts

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Off Site Support

C.I., Technical Support & Warranty


Continuous Improvement
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

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Off Site Support

Business System and Financial Management


Parts and Work Order Management
Parts Requests and Additions Work Order Opening Invoicing Requirements Cost Control Work in Progress Backlog Parts Non-moving Parts

Scheduled Reporting

Fleet Costs Management


Expenditure versus Budget Projected Costs High Costing Machine Areas Machine Specific Reports Re-alignment of maintenance practices along with expenditures

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Off Site Support

Rebuild Logistics
Fleet Long Life Component Projections 12 month Planning process
Planned / Unplanned Component Replacement

Pre-Prepared 100% Rebuild Kits

Component delivery to C.R.C. Workshop (Component Tags and Repair Instructions)

Pre-Ordering 100% Kits for all Components (Seafreight)

The 3 week Component Return Cycle


Component Return to M.A.R.C. Site C.R.C. Strip, Rebuild & Test (Following R.P.I. Administration)

Pre-Prepared Labour Enhancements and Structure Upgrade


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Staffing

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

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Staffing

Management Structure
Project Manager

Maintenance Supervisor

SHE

Maintenance Planner

Parts Supervisor

Service Bay Supervisor

Welding Supervisor

Electrical Supervisor

Shift Supervisor

Workshop Supervisor

Abraham Sackey Alfred Tawiah Samuel Ayiku Francis Gyakye Alex Baah Kwasi Amande Isaac Nyarko Emmanuel Ewudzi Dominic Cudjoe Asare Baidoo Benjamin Ahorsey Buami Xola GeorgeNkrumah CyrusSampson Larbi Fuel Bay Inspectors Dan Venance Samuel Incoom Paul Bluvi Prince Yeboah Lord Cudjoe Wakson Supervisor Seidu Dawuda Ibrahim Abubakari Francis Kwofie Augustine Tsiwah Joel Ankomal lBen Takyi Kwesi Ano

Daniel Acheampong Lawrencia Ofosu Gyan Martin Satekla Gabriel Cudjoe Hagar Nyamekye Kofi Gyimah Thomas Appiah Lawrence Mensah

Ebenezer Oppong Christian Kumordzi Anthony Aquach George Blay

Samuel Boadi Bramsco Isaac Kyereboah Wilson Vordzorgbe John Opoku Emmanuel Nsiah Adams Gaddiel Amoako Yussif Seidu Alfred Yankson

Isaac Obeng Abdul Karim Nicholas Kuevi Fuseini Amandu Moses Ativo Richard Kofi Norgbey Samuel Danquah Agbessi Bamidele Kingsley Appiah Richard Nyanney James Bilini Samuel Arthur Bekai Darku JohnTanko AyubaBen Vondey Maxwell Boaitey Crane operators Ebenezer Asimeng

Admin Manager

Vehicle Info Manager

Fred Akuffo Emmanuel Amu Charles Mends William Asare Donkor Emmanuel Bart-Plange James Abban (C) James Asamoah (C) Hose Technician Rowland Bessieh

Terrence Blankson Daniel Adjah John Oko Amarteifio Samuel Okine

Lube Truck Edward Kwame Kyi Akakpo Michael Franklin Kwofie Peter Danso William Ampah Patrick Boakye CIL Inspectors George Solomon Richard Mensah John Kyei Bosco

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Staffing

Logistics
Transport
Staff transport to/from work Expatriate travel to/from site for leave/training Leave / Training Flights Visitor travel arrangements External trainers On site accommodation for expatriate staff
Furniture Kitchen Utensils Cleaning and Laundry

Accommodation

Hotels Local accommodation for training Visitor and Management Hotel Costs Local Food supply
Dayshift/Nightshift

Food

Expatriate Meals Visitor / Management Meals

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Staffing

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

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Critical Success Factors

Components vs. Machines


How many spare components do I need on 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 10 Equipment Models
>90% Availability <1 month turnaround <10% failure rate >80% Rebuild Life

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Critical Success Factors

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 Proximity to Component Changeouts Specialised Work Required
Welders (Body repairs)

Fleet Age

Breakdown % per day Quality of work Scope Capabilities Training Needs PM Supervisor Toolstore Backlog Store Maintenance Planner

Workmanship

Key Areas

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Critical Success Factors

Component Life & Planning


Component Life Extention
Increasing component life does not mean decreasing cost per hour Increasing component life and achieving budgeted rebuild cost will decrease cost per hour Rear Axle Life
Kidney Looping Condition Monitoring High efficient filters Continuous Monitoring

Oil Cleanliness

Fleet SMU Proximity Implication


Try to avoid Component Change-Out Peaks Be aware of the possibility of component potential failure increase. Plan 12 months in advance Ensure Parts and Rebuild Centres are aware Reman option Recondition option New option After/ Before Failure option Condition Monitoring option

Replacement Strategy

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Critical Success Factors

Early SMU Management


Early Hour Principles
Be aware of the Honeymoon Period! Utilize Training Opportunity Keep Work Efficiency High Ensure the Asset is looked after, not the breakdown Ensure Systems and Procedures are adhered 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 Component Replacement

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Critical Success Factors

Crane & Fuel Truck


Crane Usage
Vital in machine build Component Changeouts
Dump Bodies

Fuel Truck Availability


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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Critical Success Factors

Utilization vs Availability
Projected utilization of fleet key to facility and maintenance planning
Components Staff Workshop Space Tooling Rebuild Centres

Utilization is directly proportionate to machine 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

On-Site Support
Set Up Costs Tooling Service Vehicles Planning Component Inventory Parts Inventory Losses Consumable Inventory Safety Operation Severity

Off-Site Support
Inventory Management Non Cat Parts Sourcing Continuous Improvement Technical Support Warranty Financial Management Business System Rebuild Logistics

Staffing
Staff Recruitment HR & Payroll Management Tree Logistics Training

Critical Success Factors


Components vs Machines Staff vs Machines Component Planning Early SMU Management Crane Availability Fuel Truck Availability Utilization vs. Maintenance Component Life

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