towards zero downtime
TRANSCRIPT
““Emerging trends to achieve Emerging trends to achieve Zero Down Time in the Era ofZero Down Time in the Era of
Maintenance Out Maintenance Out Sourcing”Sourcing”
Pinaki Roy
It is the task of the It is the task of the maintenance function to maintenance function to support the production support the production
process with adequate levels process with adequate levels ofof availabil i ty, rel iabil i ty availabil i ty, rel iabil i ty andand operabil ity operabil ity at an at an acceptable acceptable
cost.cost.
Basic Maintenance Objectives Basic Maintenance Objectives
Maintenance PhilosophiesMaintenance Philosophies
InspectionsConditionMonitoring
Predictive
ScheduledOverhaul
ScheduledService
ScheduledReplacement
Use Based
Preventive CorrectiveDesign-out
MaintenanceStrategies
THE MAINTENANCE THE MAINTENANCE TRIANGLETRIANGLE
CONTROL-CMMS
PLANNING
PROCEDURES
PHILOSOPHY
OPERATIONS
Measurement of MaintenanceMeasurement of MaintenanceDefinit ionsDefinit ions
““ Available Hours” Available Hours” means Maximum Theoretical Hours means Maximum Theoretical Hours minus total Engineering Down Time.minus total Engineering Down Time.““ Maximum Theoretical Hours” Maximum Theoretical Hours” means the total effective means the total effective hours available for mining operations.hours available for mining operations.““ Engineering Maintenance Time” Engineering Maintenance Time” means all equipment means all equipment down time due to planned maintenance.down time due to planned maintenance.““ Engineering Down Time” Engineering Down Time” means all equipment down time means all equipment down time due to un planned maintenance and breakdown repairs.due to un planned maintenance and breakdown repairs.““ Availabil i ty” Availabil i ty” means Available Hours divided by Maximum means Available Hours divided by Maximum Theoretical Hours and expressed as a percentage.Theoretical Hours and expressed as a percentage.““ Uti l ized Hours” Uti l ized Hours” means the operating hours taken from the means the operating hours taken from the equipment hour meters. On some equipment utilised hours equipment hour meters. On some equipment utilised hours have to be expressed more specifically e.g. on drilling have to be expressed more specifically e.g. on drilling equipment there are percussion hours and engine hours.equipment there are percussion hours and engine hours.““ Uti l izat ion” Uti l izat ion” means Utilized Hours divided by Available means Utilized Hours divided by Available Hours and expressed as a percentage.Hours and expressed as a percentage.
Objectives of Maintenance Objectives of Maintenance in Miningin Mining
Availabil i tyAvailabil i ty - Uptime, non-failed state. - Uptime, non-failed state.
Higher Availabil i tyHigher Availabil i ty = More Tons = More Tons
Reliabil i tyReliabil i ty - MTBF, MTTR (number of - MTBF, MTTR (number of breakdowns)breakdowns)
(Mean Time Between Failure, Mean Time To (Mean Time Between Failure, Mean Time To repair) repair)
Operabil i tyOperabil i ty - Ability to sustain production - Ability to sustain production
CostCost - Rs/ton - Rs/ton
Trends in Equipment Trends in Equipment Development inDevelopment in
the World Today !the World Today !
The “Age of Knowledge”The “Age of Knowledge”
We live in t imes of unprecedented growth in We live in t imes of unprecedented growth in the expansion of “knowledge”. The total the expansion of “knowledge”. The total “knowledge” in the world doubled from man’s “knowledge” in the world doubled from man’s f irst recorded history to the birth of Christ & f irst recorded history to the birth of Christ & thereafter it took 1,600 years to redouble thereafter it took 1,600 years to redouble and today is estimated to be redoubling and today is estimated to be redoubling every 2 to 4 yearsevery 2 to 4 years““ Knowledge” once applied to specif ic Knowledge” once applied to specif ic problems becomes “technology” problems becomes “technology”
THE “TECHNOLOGY” AGETHE “TECHNOLOGY” AGE
““ Technology” when applied effectively to a segment of Technology” when applied effectively to a segment of the economy, results in higher productivity, higher the economy, results in higher productivity, higher eff iciency, and lower costsefficiency, and lower costs
The sustained growth rate in western economies of 3 to The sustained growth rate in western economies of 3 to 4% over many decades is attributed to productivity gains 4% over many decades is attributed to productivity gains through the introduction of technology, not population through the introduction of technology, not population growth or people working harder.growth or people working harder.
OEM Companies are investing approx 3% of turnover OEM Companies are investing approx 3% of turnover into R&D, and are really technology solution providers, into R&D, and are really technology solution providers, with a focus on improving customer’s productivity.with a focus on improving customer’s productivity.
Further Trends
Trends in Equipment Trends in Equipment DevelopmentDevelopment
The “Human Rights” ageThe “Human Rights” age
Increasing trends to ensure people work Increasing trends to ensure people work in “safe” and “healthy” working in “safe” and “healthy” working environmentenvironment
Increasing Government and Union Increasing Government and Union involvement in your working environmentinvolvement in your working environment
Unwill ingness of people to accept poor Unwill ingness of people to accept poor working condit ionsworking condit ions
Environmental TrendsEnvironmental Trends
The “Environmental” ageThe “Environmental” age
Increasing trends to ensure Increasing trends to ensure mining practices are mining practices are environmentally friendly environmentally friendly Increasing & monitoring and Increasing & monitoring and control by Government and control by Government and NGOs of mining operationsNGOs of mining operationsCommunity and local Community and local organizations sensit ive to issuesorganizations sensit ive to issues
DEFINITION OF DEFINITION OF PERFORMANCE/EFFICIENPERFORMANCE/EFFICIEN
CYCYPerformance – “execution of an action” Performance – “execution of an action” - “fulf i lment of a promise or - “fulf i lment of a promise or request”request”
Efficiency – “the quality or degree of Efficiency – “the quality or degree of being efficient”being efficient” - “as measured by the production - “as measured by the production and cost”and cost”
Productivity – (output value)/(total Productivity – (output value)/(total input costs)input costs)
Mining ProductivityMining Productivity
Productivity = Productivity = OutputOutput InputInput
Equipment = Capital cost + Operating Equipment = Capital cost + Operating costcost
Consumables = Tyres, lubricants, fuel, Consumables = Tyres, lubricants, fuel, buckets etcbuckets etc
How Inputs come about….How Inputs come about….
(Equipment+Labour+Consumables+Infrastru(Equipment+Labour+Consumables+Infrastructure)Rscture)RsEquipment = Capital cost(10%) + Operating Equipment = Capital cost(10%) + Operating spares cost(10%)spares cost(10%)Labour cost = Mining labour(30%) + Labour cost = Mining labour(30%) + Maintenance labour(5%)Maintenance labour(5%)Consumables = Tyres, lubricants, Consumables = Tyres, lubricants, fuel,buckets,etc (30%)fuel,buckets,etc (30%)Infrastructure = Electricity, services, etc Infrastructure = Electricity, services, etc (10%)(10%)Revenue or effective use of equipment ????Revenue or effective use of equipment ????
IMPROVED PRODUCTIVITYIMPROVED PRODUCTIVITYMEASURE MEASURE �� CONTROL CONTROL �� OPTIMIZE OPTIMIZE
Continuos Improvement
Planning
Production Execution
Follow Up
Real-time Information
Sharing
ReportsTarget
Monitoring Info
Machine Missions
Continuous process enables process optimization Accurate real-time information is available
•Get key personnel involved as soon as possible•Buy in at all levels is crucial•All parties must work towards the same GOALS•It must be a WIN-WIN situation or will not work
How to Implement Successfully ?
•The Keyword is TEAMWORK
REPORTING
•Have regular meetings with all levels.•Review achievements against KPIs and also costs•Identify problems and concerns, and draw up action plans•Work on a number of improvement projects as a team
Measurement of Long Term Success
•Appoint a steering committee, of personnel from all the levels •Do monitor of all aspects of operation, review technology options.•Benchmark against other operations•Set long term goals and KPIs based on sustained improvements.•Meet at least once in a week to review•Appreciate each other on the achievements
LOOK FORWARD ON IMPROVEMENT
Dedicate t ime to monitor the Dedicate t ime to monitor the results ,results ,
it ' s the path to salvationit 's the path to salvation Look forward with safety
and lastly but most important
BE STRATEGIC !
Outsourcing-OverviewOutsourcing-Overview
• Outsource- is the arrangement for (work)Outsource- is the arrangement for (work) to be done by external agencies. to be done by external agencies.
OBJECTIVEOBJECTIVE
Opportunity to focus on core business for desired Opportunity to focus on core business for desired credibility with profit.credibility with profit.
Cost effective- Without compromising onCost effective- Without compromising on Quality, Safety & Customer Quality, Safety & Customer
delight. delight.
PhilosophyPhilosophy
Outsourcing is not merely contracting out.Outsourcing is not merely contracting out.
Contracting – aims to earn profit, with no value Contracting – aims to earn profit, with no value addition.addition.Outsourcing – to partner with service providers Outsourcing – to partner with service providers
for specific business process to get better , for specific business process to get better , faster and financial benefit.faster and financial benefit.
A Business Partner…A Business Partner……..…..
Assess capabilityAssess capability
To Reduce To Reduce Operating & capital cost.Operating & capital cost.InventoryInventoryOver headOver head
Improvement in core competency.Improvement in core competency.Help in skills.Help in skills.As a partner on cost saving measure.As a partner on cost saving measure.
Look for the Right AgencyLook for the Right Agency
Words of CautionWords of Caution
Ensure –Ensure –Deal for Deal for
Cost containment & quality standards.Cost containment & quality standards.Production commitment.Production commitment.Non performance penaltyNon performance penalty..
Capability to induce improvementCapability to induce improvement..Contingency plan for fall back.Contingency plan for fall back.Action plan for counter in house resistance.Action plan for counter in house resistance.
Setting Goals and ObjectivesSetting Goals and ObjectivesOwners OH&S Productivity Environment Optimisation of fleet Commercially viable
Party OH&S Reliability Availability Environment Commercially viableSafety
Action PlansPriorities
ResponsibilitiesChange of Scope
Reporting ScheduleDispute Resolution
Management Team
Operating Team
Mine Management Site Management
Creating the EnvironmentCreating the Environment
Continuous Improvement
Consolidate gains
Measure Outcomes
Empowerment
Publish short term wins
Communicate the Vision
Develop vision and strategyAVAILABILITY
RELABILITY
MAINTAINABILITY
TOTAL
COST
of
OWNERSHIP
PRODUCINGPERFORMANC
ECONTRACT
TRAINING CONTRACT
PREVENTIVE MAINTENANCECONTRACT
COST & PRODUCTIVITYCONTRACT
PERFORMANPERFORMANCECE
RELIABILITYRELIABILITY
AVAILABILITYAVAILABILITY
FIXED FIXED PARTSPARTS& SERVICE& SERVICE
FIXED PARTSFIXED PARTSPRICEPRICE
INTERMITTENT PARTIAL INTERMITTENT PARTIAL INTEGRATEDINTEGRATED
EQUIPMENT SUPPLIER INVOLVEMENT
COMPONENT EXCHANGE CONTRACT
SPARE PARTS CONTRACT
COST & AVAILABILITYCONTRACT
COMPETENCY
PROFIT / LOSSSHARING
FIXED FIXED PARTSPARTS& LABOUR& LABOUR
1
2
3
4
5
6
7
8
Performance Contracts on MaintenancePerformance Contracts on Maintenance
Benefits of Outsourcing Benefits of Outsourcing
• Outsourcing is successful in that it Outsourcing is successful in that it increases product quality increases product quality
• Lowers costsLowers costs• Increases productivityIncreases productivity && If implemented and monitored If implemented and monitored
properly – properly – CAN BRING ABOUT A ZERO CAN BRING ABOUT A ZERO
DEFECT CULTUREDEFECT CULTURE