Transcript Slide 1

The Role of Defect Elimination in
Reducing Hazard Exposure
Presented by: Stuart Tomlins
Callide Mine
Context
Callide Mine……
 10 Mtpa open cut thermal coal
 Located 1.5hrs S.W. of Rockhampton
 450 full time employees
 Overburden is primarily removed by 2 draglines, 1 shovel
& 1 excavator
 The excavator & shovel are supported by a fleet of 15 x
270t payload rear dump trucks (EH4500’s)
This presentation discusses the EH4500
truck fleet improvement project & assesses
the impact on hazard exposure
Truck Fleet Availability by Year
3 years of declining performance…………..
EH4500 Fleet Availability 2003- Q1, 2008
100%
EH4500 Fleet Availability (%)
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
2003
2004
2005
Year
2006
2007
Actual
Q1, 2008
Target
…………..required action
Taking Action
To reverse the trend a number of processes
commenced to address the EH4500 availability:
 Reliability
data analysis *
 Dedicated team assigned to plan and execute the
defect backlog reduction*
 Scheduled service process review
 Defect elimination*
 Hitachi EH4500 users forum
Reliability Analysis of EH4500 Downtime
Top 20 downtime components for EH4500 fleet July to Dec 07
1200
Hitachi EH4500 Rear Dump Improvement Plan
Current Performance
Hitachi Availability 2005 - 2008
80
80
Percentage
100
Percentage
1000
Hitachi Availability 2003 - 2008
100
60
40
20
60
40
20
0
J
an05
Ma
r05
Ma
y05
Jul05
Se
p05
No
v05
J
an06
Ma
r06
Ma
y06
Jul06
Se
p06
No
v06
J
an07
Ma
r07
Ma
y07
Jul07
Se
p07
No
v07
J
an08
0
2003
2004
2005
Month/Year
EH4500 Availability
800
Budget
EH4500 Availability
Pareto Analysis
Critical Issues
1200
1000
800
Hours
2008
How to reduce ‘Wait Labour’ delays for mechanical repairs to an acceptable level.
How to effectively manage the backlog, completing defects in conjunction with the PM schedule.
How to reduce ‘Wait Labour’ delays for tyre maintenance to an acceptable level.
How to improve technical skills of workforce to reduce trouble shooting time on Engine Faults.
How to implement product improvements with minimal impact to production.
How to structure the department to support the truck fleet on 7DR
How to improve focus and urgency around the performance of the rear dump fleet.
How to
Hitachi
andmaintenance
improve their
focusare
onnot
improving
fleet
What
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Operator
induced
events
minimised
eg.reliability.
tyre damage, operational conditions impacting on
fatigue life of chassis.
Top 20 downtime components for EH4500 fleet July to Dec 07
600
400
200
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Ty
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0
400
Type of downtime
Improvement Plan
Increase support and focus from
Hitachi
Type of downtime
Delayed
Extend Bridgestone tyre fitter coverage to 7 days / wk
Stuart Tomlins
30/04/2008
↓ in 'Wait Labour' delays.
Scheduled tyre changes integrated into Mobile Maintenance Schedule
Sven Gronbach
30/03/2008
↑ Availability
Complete installation of double gutter rims. (7 Trucks)
Sven Gronbach
30/05/2008
↑ Availability
Review Tyre Specification & application for operation in Trap Gully
Stuart Tomlins
1/04/2008
↑ in Scrap tyre life
Engage one Detroit fitter Mon-Fri for engine fault finding and maintenance.
Conduct engine specific training (Improve the technical skills of
maintenance personnel)
Stuart Tomlins
3/03/2008
↑ Availability
Stuart Tomlins
30/05/2008
↑ Availability
Review the level of routine & PEX spares held at site and Detroit in Mky.
Stuart Tomlins
1/04/2008
↓ in 'Wait Parts' delays.
Complete
Develop contingency plan for engine repower on Rear Dump 1154
Implement contamination control for final drives by implementing an oil
filtration process.
Review final drive oil specification with Hitachi & Shell wrt extending
component life.
Stuart Tomlins
17/03/2008
↑ Availability, ↓ in 'Wait Parts'
delays.
Complete
Danny Jamieson
1/04/2008
↑ Availability
Danny Jamieson
17/03/2008
↑ Availability
Engage Hitachi (OEM) to improve Wheel motor and grid blower reliability.
Danny Jamieson
1/06/2008
Independent A/C specialist to review OEM system.
Conduct a review of A/C spares holding onsite
Update maintenance strategy to include a 12mth major service.
Danny Jamieson
Stuart Tomlins
Sven Gronbach
7/04/2008
1/04/2008
1/04/2008
Implement the following electrical updates : Seimens Data isolators, 5XH
plug upgrade to main alternator & Temp sensor upgrade to wheel motors.
Stuart Tomlins
1/05/2008
Implement bearing assembly upgrades to main blower.
1/05/2008
Stuart Tomlins
1/05/2008
Stuart Tomlins
1/05/2008
Engage dedicated tradesmen (2) for a two month period.
Conduct Daily Downtime & Planned Work compliance reviews identifing
corrective actions. (2 month period)
Stuart Tomlins
10/03/2008
Stuart Tomlins
10/03/2008
Communicate improvement plan & weekly fleet performance to crews
Modify the Maintenance Structure to support EH4500 fleet operating on
7DR
Review the onsite Hitachi Project Managers role and expectations to align
with Callides requirements.
Stuart Tomlins
15/03/2008
Sean Halliday
Hold monthly EH4500 improvement meetings with Hitachi.
Danny Jamieson
↑ Availability
↓ in 'Wait Parts' delays.
↑ Availability
↑ Availability
↑ Availability
↑ Availability
Complete
Completed. No problems.
Complete
Not done yet. Currently doing stat
training.
Complete
Complete
Modifications being trialled
Parked. A/C performance has
improved thru other actions.
Complete
Complete
Complete
Complete
Complete
↑ Availability, ↓ in 'Wait Labour'
delays.
↑ Availability, ↓ in 'Wait Labour'
delays.
Complete
Complete
1/04/2008
↑ Availability
↑ Availability, ↓ in 'Wait Labour'
delays.
↑ Availability, ↓ in 'Wait Labour'
delays.
17/03/2008
↑ Availability
Complete
4/03/2008
↑ Availability
Complete. Users forum.
Complete
Complete
Complete
Siemens 123
Stuart Tomlins
Implement front wheel bearing retainer plate upgrade.
Dedicated Supervisor allocated to EH4500 for two months period to drive
scheduled maintenance tasks and generate focus on completing
maintenance backlog.
↑ Availability
Park. Too expensive.
Parked. No value at this stage.
Hoist Cylinder
Increase focus and urgency on
executing the maintenance
strategy.
↑ in Scrap tyre life, ↓ in tyres
scrapped due to cuts.
Electrical fault
Implement 'known' EH4500
Product Improvements
By When
Lube Fault
Improve Air Conditioner system
reliability
30/05/2008
Steering
Brakes/retarder
Strut
Blower
Engine code
Coolant leak/low
Siemens link/ fault
Front wheel Bearing/Hub
Air conditioner
Axle/drives
Tyres
Improve driveline reliability
Who
Oil leak
0
Status
Rod Nichols
Fuel tank/hydraulic tank
Reduce downtime related to
Engines
Action
Steel work/Tray
200
Performance Measures
BI Project - Tyre life improvement
Minor maintenance (blank)
Problem Statement
Reduce downtime related to Tyre
Management
Engine fault
Hours
2007
2005 - 2008 included trucks 1151-1164 (full fleet)
2003 included trucks 1151-1156
2004 included trucks 1151-1160
600
2006
Year
Budget
Defect backlog reduction
120
60%
Work Orders
MA%
Improvement Project Focused on…..
•Reducing Work Order backlog
•Implementing a number of improvements
One Year Target (%)
Three Year Target (%)
This was done by…..
•Developing a plan
•Assigning a dedicated supervisor & labour
resource
•Focussed effort to reduce backlog
Fleet Availability (%)
65%
Mar-09
140
Feb-09
70%
Jan-09
160
Dec-08
75%
Nov-08
180
Oct-08
80%
Sep-08
200
Aug-08
85%
Jul-08
220
Jun-08
90%
May-08
240
Apr-08
95%
Mar-08
260
Feb-08
100%
Jan-08
# of Outstanding Jobs
EH4500 Availability vs Workorder Backlog
280
Maintenance Injury Rates Through the
Projects Duration
Total Maintenance Injuries vs Availability on Trucks
90%
7
Defect Elimination Campaign
4
75%
3
70%
2
65%
1
Truck Fleet Availability
Total Injuries in Maintenance
Nov-08
Oct-08
Sep-08
Aug-08
Jul-08
Jun-08
May-08
Apr-08
Mar-08
0
Feb-08
60%
Jan-08
Availability (%)
5
80%
2 per. Mov. Avg. (Total Injuries in Maintenance)
Injury Moving Average
6
85%
Some perspective
2831 defects over 12 month period (EH4500)
Estimate at least 5 hazards per defect
14155 hazards on 1 fleet
Hazard exposure
Risk = Consequence x Likelihood
Defect elimination
Reduced exposure
Example Defect Elimination Projects
Problem-5XH Alternator Plugs ground faults
Root Cause
Dust & water ingress
from poor plug location
& inadequate sealing
Benefit
Solution
•Reduced downtime (34hrs/yr)
•Hard wire cables into termination
strip
•Reduce maintenance costs
•Reduced hazard exposure
•Replace plug with gland plate
Problem – Premature final drive failures
Root Cause
•Oil viscosity too low
•Wear metal
generated causing
wide spread
deterioration
Benefit
Solution
•Reduced gear and bearing wear
•Change to costly synthetic lube
•Maximise life of oil & final drives components
•Implement kidney filtration
•Reduce hazard exposure by extending the
time between maintenance & reducing
failures
Problem – Reverse Light Damage
Root Cause
Poor light location
Benefit
Solution
Reduced downtime by 50hrs per yr
Relocate the light position
to under the rock deflector
shield
Reduced maintenance costs
Reduced hazard exposure fixing these
lights
Problem – Starter Motor Testing Duration
Root Cause
Extended service
duration due to testing
method required to
ensure starter motors
are both functioning
Benefit
Solution
•Reduction of 40 hours
servicing per year
By installing 2 switches in the cab, the serviceman
can turn one starter motor off via the new
switches, test with ignition switch. Repeat for the
second starter motor. The red guards give a
visible indication of the position of the switch to
overcome leaving in the wrong position
•Reduced hazard
exposure
Problem – Difficult access to check pressure
& re-charge front struts
Root Cause
The cause is due to the
recharge points facing
towards the rear of the
truck. Access via a mobile
platform is impeded by
the steering arm
Benefit
Solution
•Safer access of existing engine
platform to check / recharge
struts
By rotating the struts around 180
degrees, this then allows the access
via the engine bay stairs/platform
•Reduction of 15 minutes per service
on each truck
Problem – Hydraulic contamination from lift
cylinder seal erosion
Root Cause
Seal Saver Fitted
Design of
radiator fan
causes
exhaust dust
to erode
cylinder rod &
seals
Benefit
Solution
•Reduced contamination levels in the hydraulic
system which will reduce the failure rate on the
hydraulic pumps and cylinders
Install Kevlar seal savers to
the lift cylinders to prevent
erosion and contamination
•Reduced hazard exposure are change outs will
occur less frequently
The benefits of the defect removal &
elimination program are:

Reduced unplanned callouts to equipment in the field

Better hazard control in planned work situations

Reduced exposure means reduced risk

Reduced maintenance costs

Increased asset performance

Cultural shift

Great teamwork and energy in finding solutions
Summary

Defect backlog management and defect elimination are
key factors in reducing hazard exposure for tradespeople

Build momentum by involving your trades teams

Solutions are generally inexpensive, simple & effective