Documentos de Académico
Documentos de Profesional
Documentos de Cultura
9 y 10 Febrero 2006
Availabilty & Utilization
100 90 Av ailability Utili ti Utilization T arget
Reliability MTBF
100 MTBF Target 80 MTBF (Hours) MTTR (hours) 7
80
60
70 60
40
20
July
0 January March May July September November February April June August October December
Maintenance Ratio MR
0.6 MR 0.5 Labor/Op. hours 0.4 0.3 Target
Reliability MTBF
100 MTBF T arget 80 MTBF (Hours) 6 5 7
May June
July
60
70 60
MTTR (hours) May June July September November August October December
80
4 3
40
20
J uly
May June
July
Maintenance Ratio MR
0.6 MR 0.5 Labor/Op. hours 0.4 0.3 0.2 0.1 0 January March February April Target
100
May June
July
Disponibilidad %
90
80
70
60
25
45
65
85
105
125
142
162
182
La diferencia........
Operacin
Disponibilidad
A:
92
B:
92
C:
88
D:
95
La diferencia........
Evale la Gestin de las Gerencias de Mantenimiento de dos operaciones A y B Op. A Enero Disponibilidad Mecanica MTBS MTTR Precision de Servicio % programados MTBS despues de PM Relacin de Mantenimiento % Servicio almacn de repuestos Backlog ejecutados por PM 88.24% 30 4 70 60 40 0.2 80 5 Op B Enero 86.96% 20 3 70 60 30 0.2 80 3
Objetivos j
z z
= P x U / C
Repara
Adan & Eva WW II
Evolucin
Tipo de Gestin vs Confiabilidad
Gerencia Lider
Planeamiento Estratgico Sistema Integrado de Informacin
Gerencia de la Persona
Responsabilidad , Autoridad Desarrollo y Reconocimiento
Trabajar Juntos hacia METAS COMUNES ... El mejor diseo para la Aplicacion Equipo operando en Aplicacin controlada y predecible Mantenimiento i i Proactivo i adaptable a los cambios en Aplicacion
Produccin
Actual versus Target Ton/day
200
Tons/day.Target Tons/day.Actual Ore. Actual
150
Ore. Target
100
50
0 January
February
March
April
May
June
July
August
September
October
November
December
Analysis
Camino Principal
Veloc.
GVW=EVW + P l d* Payload*
Observacin en campo Sistemas en la Cabina, data del VIMS Nueva tecnologa (CAES) Sistema Dispatch Reportes de Produccion others.
Modo de Operacion
Recoleccin de Datos
C Solo Vims
Etapa de Carga
Del.Derecho
16000
Del.Izquierdo
Post.Izquierd
Post.Derecho
14000
12000
10000
8000
6000
4000
2000
18000
Giros
16000
14000
12000
10000
8000
6000
4000
2000
0 0
27 99 175 243 310 380 456 530 589 657 733 809 885 945 998 1056 1094 1105 1127 1182 1258 1306 1314 1327
20,000 18,000 16,000 14,000 12,000 10,000 COMPOSITE STRUT PRESSURES S (kPa) 8,000 6,000 4,000 2,000 0 -2,000 -4,000 -6,000 -8,000 -10,000 -12,000 -14,000 14 000 -16,000 -18,000 -20,000 37 107 186 248 325 426 540 685 802 884 946 1021 1091 1143 1183 1223 1268 1334 1420 1496 1576 1613 1629 1635
Management Line
Management Line
20,000 18,000 16,000 14,000 12,000 10,000 COMPOSITE STRUT PRES SSURES (kPa) 8,000 6,000 4,000 2 000 2,000 0 -2,000 -4,000 -6,000 -8,000 -10,000 -12,000 -14,000 -16 000 -16,000 -18,000 -20,000 1 93 201 319 432 552 660 768 876 986 1096 1206 1315 1423 1532 1640 1749 1832 1934 2043 2177 2369 2531 2571 2605
Management Line
Management Line
La diferencia........
Mina
Disponibilidad
A:
92
B:
92
C:
88
D:
95
PRODUCCION
Reportes Disponibilidad Produccion
PLANEAMIENTO (P)
Backlog Programa Reunin (S) Prod/Mant
Orden T. T Inspect
REPUESTOS (S)
Dispon. Entrega
MANTENIMIENTO(E) Taller
Control Calidad
La experiencia ha mostrado la necesidad de ciertas f funciones i en todo Sistema Si de A Administracin i i i del Mantenimiento Mantenimiento Preventivo (E) Monitoreo de Condiciones (P) Administracin de backlogs (P) Administracin de Componentes (P) Administracin de Repuestos (S) Taller de Mantenimiento,Campo,Taller Reparacion (E) Sistema de Informacin / CMMS ERP (A) Anlisis de Rendimiento del Sistema,Kpi (P) Administracin Ad i i t i de d P Problemas bl o Analisis A li i RCM (A)
Benchmarks
operaciones.. Administracion de cargas, demoras, tiempos de carga, tiempo de exchange , produccion, costo por tonelada, etc..
EQUIPMENT
METRICS
1 Machine History
(Hours/SMU/Work Done)
MANAGEMENT
WHAT CAN I OBTAIN WITH
Age of Equipment
(& kind of Life)
World Class Mines Benchmarks
CALCULATION
WHAT IS NEEDED TO
- SMU
Operation Hours
Availability y Utilization
A=
x 100 (%)
Mine operation requirements satisfaction level Equipment Use. Labor/Parts, Burden estimation Reliability A= Turnaround (Effectiveness & Response of Repairs) Effort invested Quality of repairs/labor Who is in control ! The Maintenance Organization or the Machine PAIN Location & Severity . Correct response to failures: - Parts Inventory - Mechanics Training - Improve inspection Programs - Operators/Pit Supervisors training - ... Fundamental information for the PROBLEM MANAGEMENT TEAM (Customer / Dealer / Factory) ( y) Planning / Scheduling Efficiency Repair Centers following planned activities ? General planning accomplishment Are I'm standing on a solid base ? MTBS MTBS + MTTR
U=
x 100 (%)
MTBS =
MTTR=
Repair Hours Control Shutdowns counter Maintenance Man-Hours Control Operation Hours Control
6 Maintenence Ratio
MR=
Maintenance Man-Hours Operation Hours Ns. of scheduled repairs Ns. of Failures or Shutdowns
% SCHEDULED WORK
SW=
x 100 (%)
80 %
Shutdowns Record identifying : Component/Sympton/Times:Repair/Waiting/ Parts & materials used/ Labor/ Causeif its known. Analysis priorities: - Costs / Availability / Reliability / Labor
YES
YES
10
SERVICE ACCURACY
SA=
x 100 (%)
Within 10 %
11
BACKLOGS CONTROL
Backlogs age Quantity Estimated hours to perform Backlogs Forms designed to capture the necessary Information / Computarized System Organization personnel commitment Consummables control S.O.S. - Results Interpretation Tests / VIMS Results . . .
YES
12
RECORD KEEPING
Information Source of the Maintenance Operation Prognostics Component Life Management Problem Management
100 %
13
TRENDS
YES
Benchmark: SI (subjetivo)
registros tiles & orientados a la accin Precisos/ Completos/ a tiempo collecione datos cada turno; registre diario; analize mensualmente;monitoree/ tendencias en toda la vida del equipo equipo.
3.) Utilizacion:
Utilizacion (%) = Horas Operacion
Horas disponibles
Porqu MTBS?
comprarse >>> mano obra en exceso,facilidades , repuestos, etc. = bajo MTTR.
La disponibilidad puede MTBS
debe ganarse >>> Sistema administracin de equipo eficiente, i.e. mantenimiento, inspecciones, backlog, g, p planeamiento/ p programacin, g , repuestos,herram.etc p ,
Alto MTBS = Confiabilidad
Reliability CONFIABILIDAD
T/MTBF R=e
Donde T = intervalo de tiempo MTBF :tiempo medio entre fallas MTBS tiempo medio entre paralizaciones (Programadas y No Programadas) g ) MTBS= Horas de Operacion/# de Paralizaciones MTTR=Horas de Paralizacion/# de Paralizaciones % Disp Disp.Mecanica=MTBS/MTBS+MTTR Mecanica=MTBS/MTBS+MTTR
T/MTBF
100% 90% 80%
R=e R e
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 100
Clculo de Confiabilidad Flotas vs Disponibilidad p Flota Dias 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 MTBS 24 48 72 96 120 144 168 192 216 240 264 288 312 336 360
AAC/2004
50 "t" t 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 "- t/mtbs t/mtbs" -1.00 -0.50 -0.33 -0 0.25 25 -0.20 -0.17 -0.14 -0 0.13 13 -0.11 -0.10 -0.09 -0 0.08 08 -0.08 -0.07 -0.07 Prob.No Falla Prob.Falla "e e ^-t/mtbs" t/mtbs "1-e^-t/mtbs" 1 e t/mtbs 36.79% 63.21% 60.65% 39.35% 71.65% 28.35% 77 88% 77.88% 22 12% 22.12% 81.87% 18.13% 84.65% 15.35% 86.69% 13.31% 88 25% 88.25% 11 75% 11.75% 89.48% 10.52% 90.48% 9.52% 91.31% 8.69% 92 00% 92.00% 8 00% 8.00% 92.60% 7.40% 93.11% 6.89% 93.55% 6.45% Prob Falla Camiones 32 20 14 11 9 8 7 6 5 5 4 4 4 3 3 MTTR 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 Disp.Mec 80.00% 88.89% 92.31% 94 12% 94.12% 95.24% 96.00% 96.55% 96 97% 96.97% 97.30% 97.56% 97.78% 97 96% 97.96% 98.11% 98.25% 98.36%
MTBS S
85 80 75 70 65 60 55 50 45 40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
MTBS 80 60 40 20
MTTR - (hours) ( )
MTTR
Availa ability - (% %)
90 85 80 75 70 65 60
5 15 25 35 45 55 65 75 85 95 105 115 125 135 145 155 165 175 185 195
MTBS - (h (hours) )
85% 86%
15
MTTR - ( (hours)
target operating range
10
94% 95%
10
20
30
40
50
60
70
80
90
100
MTBS - (hours)
R eliability (M TB S )
100 M T BS 80 MTBS (hou urs) Target 7
60
70 60 50 40 January M arch M ay July S eptem berNov em ber F ebruary A pril June August O ctober Decem ber
40
20
0 January M arch May July S eptem ber N ovem ber February A pril June A ugust O ctober D ecem ber
M aintenance R atio M R
0.6 MR 0.5 Labor/Op. hours 0.4 0.3 0.2 Target
Majo r D rivers
Majo r A ction s
0.1 0 January M arch M ay July S eptem ber N ovember February A pril June A ugust O ctober December
G E N ER A L PE R FO R M A N C E M ET R IC S
MTTR (hours)
M MR
MTBS - (hours)
Service Accuracy
450 Lower Lim it 400 Intervals (hou urs) 350 300 250 200 150 100
% Services within n Range 100
Service Accuracy
Service Accuracy 80 Target
60
40
20
01/03/96 02/09/96
03/18/96 04/18/96
05/18/96 06/30/96
07/27/96 09/07/96
10/24/96
0 January March May July Septem ber Novem ber February April June August O ctober Decem ber
Services Perform ed
% Scheduled Shutdow ns
100 % Scheduled % Scheduled Shutdown ns Target 80
Major Drivers
60
40
Major Actions
20 January March May July Septem ber Novem ber February April June August October Decem ber
0 0 0.00 0.00
32 16 0.16 0.19
0 0 0.00 0.00
96 48 0.48 0.54
0 0 0.00 0.00
Note:
90.00 % 79.12 %
Situation Analysis
C O M PO N EN T R EPLA C EM EN T PR O G R A M
Transm issions
H ours Thousands
0 xm sn1 xm sn2 xm sn3 xm sn4 xm sn5 xm sn6 xm sn7 xm sn8 xm sn9 9 xm sn10 xm sn11 xm sn12 xm sn13 xm sn14 xm sn15 5 10 15
D iff1 D iff2 D iff3 D iff4 D iff5 D iff6 D iff7 D iff8 D iff9 D iff10 D iff11 D iff12 D iff13 D iff14 D iff15 0
D ifferentials
Hours Thousands
5 10 15
Target
Target
C O M PO NEN TS A C C U M U LATED H O U R S
9.0% 20.0%
30
% of Total Cost
25 20 15 10 0 5 0
31.0%
July
August
Septem ber
O ctober
N ovem ber
D ecem ber
80 Availability (%) 60
23.0%
30 40 20 10 0 20 0
July
August
Availabilty Goal
July
August
September
October
November
December
12.0%
8.0% 10.0% Engine XMSN/TC Dif/Finals Electrical Fram e Hydraulic Tires PMs O thers
7.0%
7.0%
6 30 5 4 20 3 10 2 1 0 0
XMSN/TC Diff/Finals Electrical Fram e Hydraulic Tires PMs Others MTTR Trend
July
August
Septem ber
O ctober
Novem ber
Decem ber
Delay Causes
Delays Dow ntim e
December 199x (last Month)
14 12
14 Tools Influence on Availab bility (%) 12 10 8 6 4 2 0 Facilities Parts Components Labor Aux. Equip. Infl. on Availability
8.1%
Facilities
21.6%
10 Delay Hours s 8 6 4
Tools
8.1%
21.6%
2 0
July y
August g
Novem ber
December
15
Situation Analysis
10
May June
July
May June
July
Backlogs Q uantity
240 Ton Truck Fleet
4 00 Q uan tity Executed 3 00
800 1000
90
Downtime ( (hrs)
80
600
Quantity of f BL
Percentage %
April M ay June July August October Decem ber Septem ber Novem ber
70
2 00
400
60
1 00
50
200
40
0 April Ma y June July Augu st Sep tem ber O ctuber Decemb er N oviem ber
0
30 April May June July August September October December Nov ember
Backlog Status
240 Ton Truck Fleet
100
80
60
0.93
40
3.04
20
0 April M ay June July August Septem ber O ctober Decem ber Novem ber
Engine Electrical Transm ission H ydraulics Steering Air Sys. PM Tires D ifferential Final Drives Brakes Suspensions F.W heels Fire Sup. Accidents Air/C ond
Percen ntage %
Situation Analysis - The Benchm arks or Targets for Q uantity, ETTR will be established. It is noticeable the increase of Backlogs and estimated tim e to repair them (ETTR). This is very dangerous; we have to im prove our reaction (clean BL List). The Nbr. of BL executed is low and constant. The quantity of Backlogs waiting for being process is affected by the location of the warehouse. The BL waiting for parts are affecting directly on the age of them , BL (>30) Corrective Actions - Considering the amount of BL "ready to go" (G reen) we will start scheduling m ore BL within the planned activities and instructing the supervisors to increase the use of the window of opportunities of the unscheduled repairs. - W e are working in the relocation of the warehouse. - W e will increase the scheduling of BL and the shop will be instructed to executed 100 % of the planned jobs.
PM Effectiveness
70 Overall MTBF 60 50 MTBF (Hours) 40 30 20 10 0 January March May July September November February April June August October December MTBF after PM
Quantity per Truck 20
MTBF Target
15
10
0 January March May July September November February April June August October December
PM Efficiency
14 12 10 Hours PM2000 8 6 4 PM250 PM500 PM1000
Situation Analysis
Target
2 0 January March May July September November February April June August October December
PM EXECUTION
A li i - Segmentacion Analisis S t i
Complejidad de Maquina = Complejidad de Sistemas & Data... Codigo de Componentes
All Data Complex Engine System Drivetrain Chassis Hydraulics Tires & Rims GET
Air Induction
Fuel Sys.
Lube Sys.
Starting
Cooling-Engine
Etc...
+ .. Repuestos, Mano de obra, T Paralizacin,# Paralizaciones... Segmentacion: S t i Sintoma Repuestos Trabajador Turno Flota Aplicacion
13.) Tendencias :
Benchmark: (subjectivo)
100% de los parmetros de monitoreo de condiciones son registrados y su tendencia es analizada, como resultado del anlisis se toman decisiones y acciones
la capacidad de pronosticar proporciona lo bsico para la estrategia g de manejo j de componentes p y reparacion p antes de falla. analisis mensual ; monitoreo/tendencia (por flotat, maquina& componente/ sistema) de 12 a 24 meses.
Torque Stall R P M
Engine Eng7
18 00
440 420
B low B y
Engine E ng7
180
17 50
400 cu feet/h hr
Lts/hr
160
RPM
17 00
140
120
16 50
100
1000
3000
5000
11000 13000
16 00
1 00 0
3 00 0
5 00 0
70 00 9000 H ours
11000
13 00 0
300
1000
3000
5000
11000
13000
O il C onsum ption
Engine Eng7 0.2
500
O il P ressure
Engine E ng7
50
SO S R esults
Engine E ng7
0.15
Lts s/hr
450
40 ppm of xx
1000 3000 5000 7000 9000 H ours 11000 13000
30
0 1 0.1
kPa k
400
20
0.05
350
10
1000
3000
5000
11000
13000
300
1000
300 0
5 000
7000
9000
11 00 0
13 000
Hours
PC R d date: t J January 199 199x
C om ponent t ID : E Eng7 7
Evaluation R esults
R ecom m endation
C O M PO N EN T C O N D ITIO N M O N ITO R IN G
MTBF
Fleet No. xx
80 70 60 50 40 30
M onthly M TBF Roll. 12 MTBF
MTBF (Hours)
1993
1994
1995
1996
1997
: : : :
M aintenance Cost/hr
Fleet No. xx
35 30 25 Cos st US$/hr 20 15 10 5 0
Situation Analysis
Monthly Cost Rolling 12
1993
1994
1995
1996
1997
La diferencia........
Operacin
Disponibilidad MTBS MTTR
A
92 70 6
B
92 23 2
C
88 80 9
D
95 20 1
La diferencia........
Evale la Gestin de las Gerencias de Mantenimiento de dos operaciones A y B Op. A Enero Disponibilidad Mecanica MTBS MTTR Precision de Servicio % programados MTBS despues de PM Relacin de Mantenimiento % Servicio almacn de repuestos Backlog ejecutados por PM 88.24% 30 4 70 60 40 0.2 80 5 Op B Enero 86.96% 20 3 70 60 30 0.2 80 3