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Reduce Down Time on 930E fleet in AJL coal mine

Reduce Down Time on 930E fleet in AJL coal mine. Li Guohui Komatsu (China) Mining Ltd. Product Spport Section Service Department 2012-3-2. Agenda 1 、 Background of AJL Coal Mine 2 、 I ntroduction of Komatsu (China) Mining Ltd 3 、 Availability review of 32 x930E fleet

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Reduce Down Time on 930E fleet in AJL coal mine

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  1. Reduce Down Time on 930E fleet in AJL coal mine Li Guohui Komatsu (China) Mining Ltd. Product Spport Section Service Department 2012-3-2

  2. Agenda 1、 Background of AJL Coal Mine 2、Introduction of Komatsu (China) Mining Ltd 3、 Availability review of 32 x930E fleet 4、 Machine down time analysis and action（GENBA） 5、 Future action plan

  3. 1、Background of AJL Coal Mine China Coal Ping Shuo Coal Co.Ltd. ATB Coal Mine AJL Coal Mine East Coal Mine • China coal is one of biggest • customer for KCML. • KCMLhave been committed to • the customer first.Support the • customer and keep Komatsu • machine high availability. • So how to reduce machine • downtime is very improtant • and urgent!

  4. 2、 Introduction of Komatsu (China) Mining Ltd. /(KCML) • Established: Sept.2010 • Total SS, 8 and Staff, 93 • Average experiece:1.98 yrs. • Machine population:595 units • - 332 Dump trucks • - 263 Construction machines Huolinhe SS M/P:58 ShengLi SS Datang SS M/P:51 Baotou SS M/P:12 Parts warehouse Zhungeer SS M/P:135 Beijing HQ Pingshuo SS M/P:262 KCRC44P Rebuild Center Chengmshan SS M/P:12 Dexing SS M/P:61

  5. 2-1、Organization Chart of KCML Product Support Div. Customer support and SS support Quality control and operation Service system operation

  6. 3、Availability of 32 x930E in AJLfor the period of Jan. 2011 to Dec. 2011 32 units 930E’s Contract Availability Review (the last unit delivered in Dec.2009 )

  7. 4、 Machine Down Time Analysis Through KCML Monthly Report Engine is the biggest factor of downtime

  8. 4-1、What is the problem on the engine and Why? Identify potential root causes for engine down time using fishbone diagram （draft)- hypothesis Quality Repair Tool & facility Material Lack of inspection tools Troubleshooting Lack of tester Manpower Assemble Management Lack of facility FC issue Design Experience No place Coolant Local parts Cold start Engine breakdown Not On time Accident Lead time Oil Sudden stop Parts error Environment No standby and stock Speed control Air Maintenance Operator Parts

  9. 4-2、Engine Down Time Analysis(Jan.2011-Jul.2011) Standby engine situation as of Jan.2012

  10. 4-3、Engine Down Time Analysis(Aug.2011-Dec.2011) 1、The engines have to overhaul based on machine operate hours （20000 Hours）. 2、What are the root causes for the long time needed for the engine to be removed and re- installed with standby engine? 8 units engine need to remove and reinstall • Unschedule overhaul • Schedule overhaul

  11. 4-4、Engine Replacement Process (GENBA) /Root Cause Analysis And Action -24 -70 -12 -6 50% of Downtime can be Reduced

  12. 4-5、Machine Troubleshooting Process (GENBA) Root Cause Analysis And Action 58% of Downtime can be reduced -24 -24 -46 -54 -14 ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ Provide 2 sets of INSITE software

  13. 4-6、Appendix 4-6-1、Standard Labor Hours From Cummins • According as customer experience and knowledge • Remove and install Reasonable hours in AJLcoal mine:84Hours 4-6-2、Estimated profit loss from machine Downtimes Note: Density/1.8 Coal:OB/1:6 Exchange rate/1:6.4

  14. 5、Future Action Plan In order to ensure the 930Ex 32 units fleet availability of more than 90% and keeping a good relationship with Customer to increase the customer satisfaction the following activities are needed and will be monitored. On going…...

  15. Thank you

  16. Appendix 1、 Improvement point by KCRC Support 2、China Coal 930E Engine OV Plan / Progress 3、Mechanical & maintance training by Cummins 4、Improvement point by Care Project 5、 Planner

  17. 1、Improvement point by KCRC Support Front view Disassemble Inspection Assemble Testing Reduce 930E Down Time & Operating Cost,to schedule OV and Reduce unschedule failure AJL: 1>、Alternator 2>、Wheel motor/7units 3>、Suspension KCRC Expansion Project

  18. 2、 China Coal 930E Engine OV Plan / Progress China Coal 930E Engine OV Plan / Progress

  19. 3、Mechanical & maintance training by Cummins

  20. 4、Improvement point by Care Project Now Machine Downtime VHMS Data OV Record SMR Before Apr.2011 Monthly report SMR of all Operation machines Only report SMR of warranty machines Record all downtime data for important model Make major failure report of warranty machines Follow all major component Change out history No major component change out record EQP Care R+M Care Web Care Have more machines operation information Make major component overhaul forecasting Reduce machines down time by scheduled OV and shorten parts lead time Lack of operation machines information No plan for major component overhaul Parts lead time was long 1、AJL Basic information collect unit 2、Machines down hours analysis 3、Machines health Monitoring

  21. 5、Planner’s “Scope of Work” System Scope of Work Purpose SS Manager Planner • Initialization and registration of newly delivered machines into KOMTRAX+. • KOMTRAX+ data download and upload to WebCARE. (Daily/Weekly) • Monitor machine health condition and register to Backlog sheet if any abnormalities. To find and report some abnormalities timely Conduct SS team to do the proactive job for preventing catastrophic failure Web Care To monitor trend data for OV timing optimization Daily Check machine performance timely (Availability/Utilization/ MTBF/MTTR) • Receive machines downtime information from customer. • Type downtime and usage data up to template sheet and upload to R+Mcare, as well as weekly downtime sheet • Analysis of machine downtime reason using R+M Care and weekly downtime sheet To find machine downtime reasons and take action for improvement R+M Care Advise to customer for component OV schedule Monthly To forecast major component OV timing • Obtain machine SMR & major component change-out history from customer. • Report machine SMR & component change-out history to HQ service department • Monitoring & scheduling component OVand advise to SS manager To accumulate machines usage for business plan EQP Care Advise to customer for customer’s parts & component stock. Monthly To prepare adequate parts & component • Registration & management of Backlogs using Backlog Management sheet. • Advise to Parts Key Person to order the necessary parts & component. • Timely open & close work order KOPEN Control and manage work order in progress To complete all the job in timely manner Daily Transparency of Stock Condition • Update SS parts & component stock condition • Report Customer’s parts & component stock condition to HQ parts Dept • Forecast parts consumption in SS Suggest to customer their own parts stockage Parts Foreman To order necessary parts for SS timely

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