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IIntroductionntroduction
WHO: WAMS are a dedicated materials handling service provider creating best practice by delivering our clients safety benefits, productivity gains and reduced costs through ‘outside the box thinking’, innovative design options and availability & maintainability focus.
Halve the costs – Double the life! - Ask us how
WHERE are we now & WHAT do we want to achieve:We concentrate our efforts on the continual Process of Improvement. By working together with our clients to understand their overall maintenance requirements we offer pro-active improvement by delivering;
Availability
Innovation
Maintainability
HOW do we get there:Incorporate a full service package which includes detailed application analyses, innovative design and engineering, through to recommendation, supply and installation. Followed up with a comprehensive condition monitoring and continuous improvement program.
WHY:Our extensive processes and systems offer;
Predictive maintenanceImproved safety through innovative designReduced inventoryCost reductionsIncreasing plant availability… to name just a few.
WHO: WAMS are a dedicated materials handling service provider creating best practice by delivering our clients safety benefits, productivity gains and reduced costs through ‘outside the box thinking’, innovative design options and availability & maintainability focus.
Halve the costs – Double the life! - Ask us how
WHERE are we now & WHAT do we want to achieve:We concentrate our efforts on the continual Process of Improvement. By working together with our clients to understand their overall maintenance requirements we offer pro-active improvement by delivering;
Availability
Innovation
Maintainability
HOW do we get there:Incorporate a full service package which includes detailed application analyses, innovative design and engineering, through to recommendation, supply and installation. Followed up with a comprehensive condition monitoring and continuous improvement program.
WHY:Our extensive processes and systems offer;
Predictive maintenanceImproved safety through innovative designReduced inventoryCost reductionsIncreasing plant availability… to name just a few.
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The The PProcess & the rocess & the SSystem – ystem – POI POI & & WMSWMS
WAMS have developed a regimented “Process Of Improvement” that identifies and details transfer maintenance issues or problems.
This detail is then comprehensively reviewed and used to form the basis of an agreed improvement program (POI).
An online “Wear Management System” (WMS) provides the tools to monitor performance and ensure compliance to the program.
The following pages outline this “Process” (POI) and the “System” (WMS).
WAMS have developed a regimented “Process Of Improvement” that identifies and details transfer maintenance issues or problems.
This detail is then comprehensively reviewed and used to form the basis of an agreed improvement program (POI).
An online “Wear Management System” (WMS) provides the tools to monitor performance and ensure compliance to the program.
The following pages outline this “Process” (POI) and the “System” (WMS).
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PProcess rocess OOf f IImprovement - mprovement - POIPOI
Audit & Application AnalysisPerformance BenchmarkingProduct & Design OptionsEngineering Detailed DraftingSupply Management
The “POI” (Process Of Improvement) incorporates the following:
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POI POI – Audit & Application Analysis– Audit & Application Analysis
A comprehensive inspection and review of each area is conducted and documented to identify any problems and to provide detailed recommendations for improvement.
A comprehensive inspection and review of each area is conducted and documented to identify any problems and to provide detailed recommendations for improvement.
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POI POI – Performance Benchmarking– Performance Benchmarking
WAMS establish strict performance requirements for all our products, against which the results are measured. By establishing benchmarks and monitoring the outcomes, we can identify and implement short and long term performance improvements.
WAMS establish strict performance requirements for all our products, against which the results are measured. By establishing benchmarks and monitoring the outcomes, we can identify and implement short and long term performance improvements.
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POI POI – Product & Design Options– Product & Design Options
Innovative Access Solutions Improve;SafetyAvailabilityMaintainability
Innovative Access Solutions Improve;SafetyAvailabilityMaintainability
Material AND design options can be considered because WAMS are not commodity suppliers.
Application specific solutions are tailored to suit the improvement requirements not just available products or materials.
Material AND design options can be considered because WAMS are not commodity suppliers.
Application specific solutions are tailored to suit the improvement requirements not just available products or materials.
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POI POI – Engineering– Engineering
3D Modelling is utilised for components and structural designs. This enables us to conduct detailed fit analysis to ensure the product fits first time, every time!
3D Modelling is utilised for components and structural designs. This enables us to conduct detailed fit analysis to ensure the product fits first time, every time!
Complex analysis such as “Finite Element Analysis” (FEA) is carried out where required.
Complex analysis such as “Finite Element Analysis” (FEA) is carried out where required.
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POI POI – Detail Drafting– Detail Drafting
Detailed arrangements and manufacturing drawings are produced once design concepts are finalised.
Detailed arrangements and manufacturing drawings are produced once design concepts are finalised.
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POI POI – Supply Management– Supply Management
To maximise cost reductions and reduce inventory levels, we can assist in establishing a supply management system that administers everything from product manufacturing and procurement to stock replacement, Just In Time (JIT) delivery scheduling and “Min \ Max” stocking levels.
To maximise cost reductions and reduce inventory levels, we can assist in establishing a supply management system that administers everything from product manufacturing and procurement to stock replacement, Just In Time (JIT) delivery scheduling and “Min \ Max” stocking levels.
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WWear ear MManagement anagement SSystem - ystem - WMSWMS
The WMS incorporates the following;
Data Collection (inspections)
Data Input (measurements & tonnes)
Area Status (live, online access)
Area Reporting (reports & action plans)
Performance Summary
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WMS WMS – Data Collection– Data Collection
Accurate ultrasonic thickness testing (NDT)Accurate ultrasonic thickness testing (NDT)
Customised measure sheets used for data collection ensure critical measure points are collected at each inspection interval.
Customised measure sheets used for data collection ensure critical measure points are collected at each inspection interval.
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WMS WMS – Data Input– Data Input
The WMS allows input of measurement date, Inspection photographs, measurement sheets and thickness values.
Other details such as tonnes or hours can also be collected
The WMS allows input of measurement date, Inspection photographs, measurement sheets and thickness values.
Other details such as tonnes or hours can also be collected
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WMS WMS – Area Status– Area Status
The WMS incorporates graphical representations of “wear status” for each zone of the area being monitored.
Being LIVE DATA, this graphic display changes EVERY DAY, so planners always know the condition of their equipment.
The WMS incorporates graphical representations of “wear status” for each zone of the area being monitored.
Being LIVE DATA, this graphic display changes EVERY DAY, so planners always know the condition of their equipment.
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WMS WMS – Area Reporting– Area Reporting
The WMS also produces detailed reports which include the parts and costs to be replaced for the report period, as well as photographs and measure sheets from the last inspection.
Customized reports are available on request
The WMS also produces detailed reports which include the parts and costs to be replaced for the report period, as well as photographs and measure sheets from the last inspection.
Customized reports are available on request
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WAMSWAMS – Case Studies – Case Studies
SAFETY – Ridgeway impact plates
WEAR – Northparkes Hoisting Skips
FLOW – Ridgeway Picking \ Trunk Chute
ACCESS – Paraburdoo CV-07
AVAILABILITY – BHPB Newman CV216 –CV218
MAINTAINABILITY – Paraburdoo “CV-06” Tripper
The WAMS philosophy is not just about wear but encompasses all
aspects of materials handling improvement.
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SAFETY SAFETY – Case Study, Ridgeway “Impact Plates”– Case Study, Ridgeway “Impact Plates”
BEFORE AFTER Material POI $
FreqPOI %
Maintenance Frequency
Material (Only)
Costs $
Projected Cost PA $
Maintenance Frequency
Material (Only) Costs $
Projected Cost PA $
2 WEEK 3,930 $102,180 7 WEEKS $ 1,850 $ 13,743 $ 88,437 350%
Before:
A20mm Q&T with 50 & 75mm cast liner system was the original installation
Issues:
High maintenance activity
Inefficient & unsafe rebuild access
High wear rate
Before:
A20mm Q&T with 50 & 75mm cast liner system was the original installation
Issues:
High maintenance activity
Inefficient & unsafe rebuild access
High wear rate
After:
Designed rotatable liners, Installed rubber compression blocks, Changed cast material specifications, Designed mobile maintenance stand
Benefits:
Reduced maintenance frequency, Safe rebuild access & storage, Availability improvement
After:
Designed rotatable liners, Installed rubber compression blocks, Changed cast material specifications, Designed mobile maintenance stand
Benefits:
Reduced maintenance frequency, Safe rebuild access & storage, Availability improvement
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WEAR WEAR – Case Study, Northparkes “Hoisting Skips”– Case Study, Northparkes “Hoisting Skips”
BEFORE AFTER Material POI $
FreqPOI%
Maintenance Frequency
Material (Only) Costs
$
Projected Cost PA $ Maintenance Frequency
Material (Only) Costs
$
Projected Cost PA $
5 WEEK $45,500 $473,200 16 WEEKS $40,000 $ 132,000 $ 343,200.00 320%
Before:50 to 180mm rubber
Issues:
High maintenance activity
Reduced volume capacity
Before:50 to 180mm rubber
Issues:
High maintenance activity
Reduced volume capacity
After:20 to 32mm tapered cast lining system incorporating saw tooth60mm impact zone with 16mm Q & T steel sides & roof
Benefits:
Reduced maintenance frequency
IMPROVED wear material distribution
After:20 to 32mm tapered cast lining system incorporating saw tooth60mm impact zone with 16mm Q & T steel sides & roof
Benefits:
Reduced maintenance frequency
IMPROVED wear material distribution
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FLOW FLOW – Case Study, Ridgeway “Picking Spoon”– Case Study, Ridgeway “Picking Spoon”
BEFORE AFTER Material POI $
FreqPOI %
Maintenance Frequency
Material (Only) Costs
$
Projected Cost PA $ Maintenance Frequency
Material (Only)
Costs $
Projected Cost PA $
1 WEEK $ 2,000.00 $ 104,000.00 7 WEEKS $ 8,000.00 $ 59,000.00 $ 45,000.00 700%
Before:
50 & 75mm Q&T liner strips and discharge ledge liners
Issues:
High maintenance activity
Restricted material flow (rockboxing)
Before:
50 & 75mm Q&T liner strips and discharge ledge liners
Issues:
High maintenance activity
Restricted material flow (rockboxing)
After:
50mm Cast lining incorporating corners on curved back wall.
Side walls & skirts are standard tiles
Benefits:
Reduced maintenance frequency
Improved material flow
After:
50mm Cast lining incorporating corners on curved back wall.
Side walls & skirts are standard tiles
Benefits:
Reduced maintenance frequency
Improved material flow
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ACCESS ACCESS – Case Study, Paraburdoo “CV-07”– Case Study, Paraburdoo “CV-07”
Before:
Fixed steel skirt plates (no adjustment)
Cumbersome dust sealing system
Issues:
Poor maintenance access
Safety issues (confined space), significant risk of manual handling injuries
Down line affect – Belt damage
Before:
Fixed steel skirt plates (no adjustment)
Cumbersome dust sealing system
Issues:
Poor maintenance access
Safety issues (confined space), significant risk of manual handling injuries
Down line affect – Belt damage
After:
Design and install a modular skirting system that can be fully maintained externally (eliminating confined space entry requirements)
Reducing risk of manual handling injuries associated with liner and skirt seal replacement.
Design and install UHMWPE primary and rubber secondary skirt seals to improve sealing
Benefits:
Full external access
Simplified skirt clamping mechanism
Quick liner replacement
After:
Design and install a modular skirting system that can be fully maintained externally (eliminating confined space entry requirements)
Reducing risk of manual handling injuries associated with liner and skirt seal replacement.
Design and install UHMWPE primary and rubber secondary skirt seals to improve sealing
Benefits:
Full external access
Simplified skirt clamping mechanism
Quick liner replacement
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AVAILABILITYAVAILABILITY – Case Study, BHPB Newman– Case Study, BHPB Newman“CV216 to CV218” Transfer“CV216 to CV218” Transfer
After:
Installed WAMS “Liner Less” chute system
Benefits:
Liner wear almost eliminated
Shutdown regime extended to 8 weeks (plant requirement not chute related)
Chute “blowouts” eliminated
After:
Installed WAMS “Liner Less” chute system
Benefits:
Liner wear almost eliminated
Shutdown regime extended to 8 weeks (plant requirement not chute related)
Chute “blowouts” eliminated
Before:
“Hood and Spoon” composite white iron block lined chute system
Issues:
Severe liner wear
4 week inspection/repair regime
Regular chute “blowouts”
Before:
“Hood and Spoon” composite white iron block lined chute system
Issues:
Severe liner wear
4 week inspection/repair regime
Regular chute “blowouts”
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MAINTAINABILITY MAINTAINABILITY – Case Study, – Case Study, Paraburdoo “CV-06” TripperParaburdoo “CV-06” Tripper
After:
Installed WAMS patented “Gridlock” liner design
Benefits:
Joint wash significantly reduced (almost eliminated)
Improved liner utilisation
Consistency in liner wear (accurate change out forecasting)
After:
Installed WAMS patented “Gridlock” liner design
Benefits:
Joint wash significantly reduced (almost eliminated)
Improved liner utilisation
Consistency in liner wear (accurate change out forecasting)
Before:
Traditional brick pattern liner system using rubber backed white iron liners
Issues:
Severe liner joint wash
Poor liner utilisation
Irregular liner change outs (individual liner cracking requiring replacement, difficult to forecast change outs)
Before:
Traditional brick pattern liner system using rubber backed white iron liners
Issues:
Severe liner joint wash
Poor liner utilisation
Irregular liner change outs (individual liner cracking requiring replacement, difficult to forecast change outs)
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WAMS WAMS – Operational Areas– Operational Areas
Olympic DamOlympic Dam
DampierDampier
MIMMIM
TelferTelfer
LihirLihir
OsbourneOsbourne
EndeavourEndeavour
PeakPeak
ParaburdooParaburdoo
TrittonTritton
Lake CowalLake Cowal
CADIACADIA
Cape LambertCape Lambert
LeinsterLeinster
NorthparkesNorthparkes
ChannerChanner
West AngelesWest Angeles
WAMS Perth OfficeWAMS Perth Office
Orange \ Parkes OfficesOrange \ Parkes Offices
Newcastle OfficeNewcastle Office
Rio Tinto (OTX), BHPB (MP)
Rio Tinto (OTX), BHPB (MP)
For WAMS contact details please click on the “Web” link above & then click “Contact Us”.For WAMS contact details please click on the “Web” link above & then click “Contact Us”.