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

…………..required action

3 years of declining performance…………..EH4500 Fleet Availability 2003- Q1, 2008

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2003 2004 2005 2006 2007 Q1, 2008Year

EH

45

00

Fle

et

Av

aila

bilit

y (

%)

Actual Target

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 DowntimeTop 20 downtime components for EH4500 fleet July to Dec 07

0

200

400

600

800

1000

1200E

ng

ine

fa

ult

Tyre

s

Axle

/dri

ve

s

Air

co

nd

itio

ne

r

Fro

nt w

he

el B

ea

rin

g/H

ub

Sie

me

ns lin

k/ fa

ult

Co

ola

nt le

ak/lo

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En

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e c

od

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Blo

we

r

Str

ut

Bra

ke

s/r

eta

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Min

or

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inte

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(b

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Ste

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ork

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Fu

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yd

rau

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Oil le

ak

Ste

eri

ng

Lu

be

Fa

ult

Ele

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ica

l fa

ult

Ho

ist C

ylin

de

r

Sie

me

ns 1

23

Type of downtime

Ho

urs

Current Performance

Pareto Analysis Critical Issues

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 engage Hitachi and improve their focus on improving fleet reliability.

Problem Statement Action Who By When Performance Measures Status

Reduce downtime related to Tyre Management BI Project - Tyre life improvement Rod Nichols 30/05/2008

↑ in Scrap tyre life, ↓ in tyres scrapped due to cuts.

Delayed

Extend Bridgestone tyre fitter coverage to 7 days / wk Stuart Tomlins 30/04/2008 ↓ in 'Wait Labour' delays. Park. Too expensive.

Scheduled tyre changes integrated into Mobile Maintenance Schedule Sven Gronbach 30/03/2008 ↑ Availability Parked. No value at this stage.

Complete installation of double gutter rims. (7 Trucks) Sven Gronbach 30/05/2008 ↑ Availability Complete

Review Tyre Specification & application for operation in Trap Gully Stuart Tomlins 1/04/2008 ↑ in Scrap tyre life Completed. No problems.

Reduce downtime related to Engines Engage one Detroit fitter Mon-Fri for engine fault finding and maintenance. Stuart Tomlins 3/03/2008 ↑ Availability

Complete

Conduct engine specific training (Improve the technical skills of maintenance personnel) Stuart Tomlins 30/05/2008 ↑ Availability

Not done yet. Currently doing stat training.

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 Stuart Tomlins 17/03/2008↑ Availability, ↓ in 'Wait Parts' delays.

Complete

Improve driveline reliabilityImplement contamination control for final drives by implementing an oil filtration process. Danny Jamieson 1/04/2008 ↑ Availability

Complete

Review final drive oil specification with Hitachi & Shell wrt extending component life. Danny Jamieson 17/03/2008 ↑ Availability

Complete

Engage Hitachi (OEM) to improve Wheel motor and grid blower reliability. Danny Jamieson 1/06/2008 ↑ AvailabilityModifications being trialled

Improve Air Conditioner system reliability Independent A/C specialist to review OEM system. Danny Jamieson 7/04/2008 ↑ Availability

Parked. A/C performance has improved thru other actions.

Conduct a review of A/C spares holding onsite Stuart Tomlins 1/04/2008 ↓ in 'Wait Parts' delays. Complete

Update maintenance strategy to include a 12mth major service. Sven Gronbach 1/04/2008 ↑ Availability Complete

Implement 'known' EH4500 Product Improvements

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 ↑ Availability

Complete

Implement bearing assembly upgrades to main blower. Stuart Tomlins 1/05/2008 ↑ Availability Complete

Implement front wheel bearing retainer plate upgrade. Stuart Tomlins 1/05/2008 ↑ Availability Complete

Increase focus and urgency on executing the maintenance strategy.

Dedicated Supervisor allocated to EH4500 for two months period to drive scheduled maintenance tasks and generate focus on completing maintenance backlog. Stuart Tomlins 1/05/2008

↑ Availability, ↓ in 'Wait Labour' delays.

Complete

Engage dedicated tradesmen (2) for a two month period. Stuart Tomlins 10/03/2008↑ Availability, ↓ in 'Wait Labour' delays.

Complete

Conduct Daily Downtime & Planned Work compliance reviews identifing corrective actions. (2 month period) Stuart Tomlins 10/03/2008 ↑ Availability

Complete

Communicate improvement plan & weekly fleet performance to crews Stuart Tomlins 15/03/2008↑ Availability, ↓ in 'Wait Labour' delays.

Complete

Modify the Maintenance Structure to support EH4500 fleet operating on 7DR Sean Halliday 1/04/2008

↑ Availability, ↓ in 'Wait Labour' delays.

Complete

Increase support and focus from Hitachi

Review the onsite Hitachi Project Managers role and expectations to align with Callides requirements. 17/03/2008 ↑ Availability

Complete

Hold monthly EH4500 improvement meetings with Hitachi. Danny Jamieson 4/03/2008 ↑ Availability Complete. Users forum.

Improvement Plan

Hitachi EH4500 Rear Dump Improvement Plan

What if Operator induced maintenance events are not minimised eg. tyre damage, operational conditions impacting on fatigue life of chassis.

Hitachi Availability 2003 - 2008

0

20

40

60

80

100

2003 2004 2005 2006 2007 2008

Year

Pe

rce

nta

ge

2003 included trucks 1151-11562004 included trucks 1151-1160

2005 - 2008 included trucks 1151-1164 (full fleet)

Top 20 downtime components for EH4500 fleet July to Dec 07

0

200

400

600

800

1000

1200

Type of downtime

Ho

urs

Hitachi Availability 2005 - 2008

0

20

40

60

80

100

Jan-05

Mar-05

May-05

Jul-05

Sep-05

Nov-05

Jan-06

Mar-06

May-06

Jul-06

Sep-06

Nov-06

Jan-07

Mar-07

May-07

Jul-07

Sep-07

Nov-07

Jan-08

Month/Year

Per

cen

tag

e

EH4500 Availability Budget EH4500 Availability Budget

Defect backlog reduction

Improvement Project Focused on…..•Reducing Work Order backlog•Implementing a number of improvements

This was done by…..•Developing a plan•Assigning a dedicated supervisor & labour resource•Focussed effort to reduce backlog

EH4500 Availability vs Workorder Backlog

120

140

160

180

200

220

240

260

280Ja

n-0

8

Fe

b-0

8

Ma

r-0

8

Apr

-08

Ma

y-0

8

Jun-

08

Jul-0

8

Aug

-08

Sep

-08

Oct

-08

Nov

-08

Dec

-08

Jan-

09

Fe

b-0

9

Ma

r-0

9

# o

f O

uts

tan

din

g J

ob

s

60%

65%

70%

75%

80%

85%

90%

95%

100%

Fle

et

Ava

ila

bili

ty (

%)

Work Orders MA% One Year Target (%) Three Year Target (%)

Maintenance Injury Rates Through the Projects Duration

Total Maintenance Injuries vs Availability on Trucks

60%

65%

70%

75%

80%

85%

90%

Jan-

08

Feb

-08

Mar

-08

Apr

-08

May

-08

Jun-

08

Jul-0

8

Aug

-08

Sep

-08

Oct

-08

Nov

-08

Ava

ilab

ility

(%

)

0

1

2

3

4

5

6

7

Inju

ry M

ov

ing

Av

era

ge

Truck Fleet Availability Total Injuries in Maintenance 2 per. Mov. Avg. (Total Injuries in Maintenance)

Defect Elimination Campaign

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

Reduced exposureDefect elimination

Example Defect Elimination Projects

Problem-5XH Alternator Plugs ground faults

Root Cause

Dust & water ingress from poor plug location & inadequate sealing

Solution

•Hard wire cables into termination strip

•Replace plug with gland plate

Benefit

•Reduced downtime (34hrs/yr)

•Reduce maintenance costs

•Reduced hazard exposure

Root Cause

•Oil viscosity too low

•Wear metal generated causing wide spread deterioration

Solution

•Change to costly synthetic lube

•Implement kidney filtration

Benefit

•Reduced gear and bearing wear

•Maximise life of oil & final drives components

•Reduce hazard exposure by extending the time between maintenance & reducing failures

Problem – Premature final drive failures

Root Cause

Poor light location

Solution

Relocate the light position to under the rock deflector shield

Benefit

Reduced downtime by 50hrs per yr

Reduced maintenance costs

Reduced hazard exposure fixing these lights

Problem – Reverse Light Damage

Root Cause

Extended service duration due to testing method required to ensure starter motors are both functioning

Benefit

•Reduction of 40 hours servicing per year

•Reduced hazard exposure

Solution

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

Problem – Starter Motor Testing Duration

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

•Safer access of existing engine platform to check / recharge struts

•Reduction of 15 minutes per service on each truck

Solution

By rotating the struts around 180 degrees, this then allows the access via the engine bay stairs/platform

Problem – Difficult access to check pressure & re-charge front struts

Problem – Hydraulic contamination from lift cylinder seal erosion

Root Cause

Design of radiator fan causes exhaust dust to erode cylinder rod & seals

Solution

Install Kevlar seal savers to the lift cylinders to prevent erosion and contamination

Benefit

•Reduced contamination levels in the hydraulic system which will reduce the failure rate on the hydraulic pumps and cylinders

•Reduced hazard exposure are change outs will occur less frequently

Seal Saver Fitted

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