GESTION DE MANTENIMIENTO DE EQUIPO MINERO

Huancayo 05 Julio 2002

ING. ALBERTO CHAVARRIA

MANAGEMENT

PRODUCTION SUPERVISION

SUCCESS

MAINTENANCE SUPERVISION

MACHINE OPERATORS AND SERVICE PEOPLE

COST INFLUENCERS
HAULING Traffic flow Truck staging Haulroad maintenance Grades and curves Length and width Dust control LOADING Techniques Optimum loads Truck spotting Conditions SUPPORT Dump tractors Trap dozers Motor graders Water wagons

DRILL AND BLAST

Fragmentation

GESTION DE MANTENIMIENTO
ALGUNOS INDICADORES DE GESTION
9DISPONIBILIDAD 9UTILIZACION 9MTBS 9MTTR 9MR

BENCHMARCKS
9AVAILABILITY: 88 - 92% 9UTILIZATION : 90 % 9MTTR: 3 6 hrs. 9MTBS: 60 - 80 hrs. 9MR: 0.2 0.3 All Jobs 0.5 Over haul only

Benchmarks for mining ...

9 Operations payload management, delays, load times, exchange times, production, cost per ton, etc.. 9 Application ... grade/ grade variation, rolling resistance, haul road maintenance, traffic flow, etc..

9 Maintenance availability, utilization, MTTR MTBS, MR , service accuracy, backlogs etc..

AVAILABILITY AVAILABILITY AVAILABILITY

9Mechanical Availability (%) = 9 Physical Availability (%) =
scheduled hours - downtime scheduled hours operating hours operating hours - downtime

Availability (%)

MTBS__ MTBS + MTTR

785 TRUCK AVAILABILITY

100 95 90 PHISICAL AVAILABILITY MECHANICAL AVAILABILITY TARGET UTILIZACION

85 80 75 Nov Dec Jan Feb Mar Apr May Jun Jul Aug

MINERA BARRICK MISQUICHILCA

785C FLEET AVAILABILITY

96 94 92 90 88 86 84 82 80 78 76 94.3 89.8 87.5 86.5 83.4 93.3 93.6 93

PERECENT %

92 88.3

86.47

87.2

JAN

FEB

MAR

APR

MAY

JUN

JUL Target

Mechanical Availability

Phisical Availability

LOST AVAILABILITY 992 FLEET

Transmission Syst 4% Lift Tilt Sensor 6% Tire 10% Others 3% Electric System 10% Steering System 7%

Grease Lines 22% PM 38%

UTILIZATION

Utilization =

operating hours available hours

Benchmark: utilization = 90%

Operational delays that affects Utilization Percent: Shifts : two or three Climate factors Blasting Planning, parts usage, tires, etc. collect & enter daily; analyze monthly; monitor/ trend over 12 month interval.

785C FLETT MINERA BARRICK MISQUICHILCA

AVAILAVILITY VS. UTILIZATION

96 94.3 92.1 89.8 94 93.3 87.5 93.4 92 86.5 93.6 88.3 83.4 93.6 90.7 86.47 93 91 87.2

PERCENT %

92 88 84 80 76

JAN

FEB

MAR

APR

MAY

JUN

JUL Utilization

Mechanical Availability

Physical Availability

MINERA BARRICK MISQUICHILCA

AVAILABILITY VS. UTILIZATION

96 93

PERCENT %

90 87 84 81 78 75 JAN FEB MAR APR MAY JUN JUL

Mechanical Availability Utilization Potencial (Physical Availability)

Physical Availability Potencial (Utilization)

MTBS
(MEAN TIME BETWWEN SERVICE)

MTBS (hours) =

operating hours number of shutdowns

shutdowns can be scheduled or unscheduled, include all maintenance and repairs except daily lubes, refueling & inspections, exclude operational delays, shift changes, lunch breaks, etc., grouped repairs count as one shutdown, monitor by fleet, machine & component/ system, indication of machine Reliability and maintenance Effectiveness, report monthly; monitor/ trend over 12 month interval.

MEAN TIME BETWEEN SERVICE

MBM
90 80 70 60 HOURS 50 40 30 20 10 0
994 WHEEL LOADER TARGET MIN TARGET MAX JAN 26.8 60 80 FEB 42.7 60 80 MAR 34.8 60 80 APR 43 60 80 MAY 53.51 60 80 JUN 58 60 80 60 80 JUL

994 WHEEL LOADER FLEET

MTTR
(MEAN TIME TO REPAIR)
MTTR (hours) =
downtime hours number of shutdowns

Benchmark (OHTs): = 3 to 6 hours (new/ mature)

shutdown criteria are the same as rules for MTBS, all delays/ wait time are included as downtime, monitor by fleet, machine & component/ system, indication of machine Maintainability/ Serviceability and maintenance Efficiency, MTTR < 3 hours indicates patching and/or high percentage of unscheduled repairs, MTTR > 6 hours indicates inefficiencies and/or excessive delays, report monthly; monitor/ trend over 12 month interval.

MEAN TIME TO REPAIR

MBM 992 G WHEEL LOADER FLEET
12 10 8

HOURS

6 4 2 0

TREND LINE

JAN 6.1 3 6

FEB 10.2 3 6

MAR 2.9 3 6

APR 7.8 3 6

MAY 6.8 3 6

JUN 7.9 3 6

JUL

992G WHEEL LOADER TARGET MIN TARGET MAX

3 6

MTBS vs. MTTR for various Availabilities

20
Availability %

85% 86%

15
MTTR - (hours)
target operating range

87% 88% 89% 90% 91% 92% 93% 94% 95%

10

MTTR 3 - 6 hrs MTBS 60 - 80 hrs

10

20

30

40

50

60

70

80

90

100

MTBS - (hours)

MR
(MAINTENANCE RATIO) maintenance (& repair) man-hours operating hours .20 to .30 (charged) .50 (overall)

MR =

Benchmark (OHTs): =

charged MR includes all workorder hours, overall MR includes workorder hours plus management, staff, supervision & idle hours, includes component R&I; excludes component overhauls & tires, can be good manpower budgeting tool, indication of efficiency of workforce, report monthly (by fleet); monitor/ trend over 12 month interval.

OVER LOAD

VIMS (VITAL INFORMATION MANAGEMENT SYSTEM)

MBM

785C TRUCK
LOAD DISTRIBUTION MD703 - MAY

300 250

TARGET PAYLOAD

10% OVER T.P.

20% OVER T.P.

237

231

216

LOAD QUANTITY

200 157 150

NO MORE THAN 10% OF TOTAL PAYLOADS

CERO PAYLOAD

114 100 65 50 12 0
LESS THAN 135 135-140 140-145 145-150 150-155 155-160 160-165 165-170 170-175 175-180 more than 180

49 12 9

17

METRIC TONS

FIN