Component life analysis for mining customers

Component Life Analysis for Mining Customers

Revised: 21 March 2010

Component Life Analysis for Customers

Overview
• Goals and Objectives
• Process - Roles and Responsibilities
• Data Required – Component Life Data and Failure Analysis Information
• Minesite Life Data
• Failure and AFA Reports
• Analysis of Data and Information - Examples
• Component Life Report - Observationsand Recommendations
• Action Plan
• Minesite Participation Guidelines

Component Life Strategy
Component Life Strategy
Optimize machine major component reliability and durability throughout
all component life cycles to achieve availability and cost per ton customer
requirements.
Through all Life Cycles – New, Rebuild, and Reman

Repair Frequency

Component Reliability – DurabilityCurve
Typical
Distribution

Quality

Durability
Desired
Distribution

Reliability

Hours

Component Life Analysis Goal

Increase Major Component Life
•

Reduce / Eliminate Failures
–
Identify causes of failure – Applied Failure Analysis (AFA)
–
–

•

Identify containment plan to manage and reduce risk
Implement solutions

Optimize Planned Component Rebuild (PCR) Life
–Define life targets and adjust as appropriate.

–

Manage PCR targets.

Benefits:

Low component life can significantly
impact machine availability

- Improved Machine Availability
- Reduced Cost per Hour / Cost per Ton
Drive Train components account for
60% +
of machine mechanical operating cost

Component Life Analysis Stakeholders
Stakeholders

Caterpillar
Global Mining• Product Support Department
• Component Life Team

Dealer

• Mine Account Management
• MARC management
• CRC Management

Minesite

• Production Management
• Reliability / Availability Management

Component Life Analysis Process & Responsibilities
•

Data Collection ( Dealer and Customer )
• Component Life Data and Information ( Minesite / Dealer )
• Component Life HoursData - prefer data for past 2 years.
• Failure Analysis Reports and Cause of Failure Information ( Dealer )
• Prefer AFAs over past 12 months

•

Analysis of Data ( Caterpillar Global Mining )
• Component Life Data
• Component Life averages, variation, and distribution
• Comparison of component life to world average
• Comparison of PCR targets to world averages
• Failure AnalysisInformation
• Identification of top causes for failures and early removals (if AFA information provided)
• Component Life Report - data summary, observations, and recommendations

• Continuous Improvement Action Plan ( Dealer / Customer )
•
•
•
•

Review findings and recommendations
Define life improvement opportunities
Define an improvement action plan
Implement improvement actionsRequired Data and Information
Required

Required

Required

Optional

Component
Name

Component Serial
Number (Cat)

Component ID
No (Dlr/ Cust)

Engine

7TR00XXX

793C

Engine

8W M00XXX

793C

Engine

8W M00XXX

793C

Engine

Unknown

793C

Engine

793C

Engine

793C

Machine
Model

Optional

Required

Required

Required

Required

DateInstalled

Date Removed

Origin for
Install

Reason for
Removal

Life Achieved

01-Sep-03

03-Mar-05

Dlr Rbld 1

Failure

9,129

03-Mar-04

17-Apr-06

Dlr Rbld 1

PCR

16,858

28-Sep-03

04-Feb-05

Dlr Rbld 1

Failure

8,822

04-Feb-04

31-Dec-06

Dlr Rbld 1

PCR

15,542

8W M00XXX

15-Dec-03

05-Nov-04

Dlr Rbld 1

Failure

5,8237TR00XXX

29-Jun-05

30-Sep-06

Dlr Rbld 1

Failure

8,280

Engine

7TR00XXX

30-Jul-05

19-Apr-06

Dlr Rbld 1

Failure

4,829

793C

Engine

8W M00XXX

793C

Engine

7TR00XXX

793C

Engine

8W M00XXX

793C

793C

Engine

8W M00XXX

793C

Engine

7TR00XXX

19-Apr-06

Spreadsheet
Template is
Available

21-Dec-06

Dlr Rbld 1...