Condition Monitoring. An Important Element of Overall Mining Equipment Management. Tim Siekmann Caterpillar Global Mining
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1 Condition Monitoring An Important Element of Overall Mining Equipment Management Tim Siekmann Caterpillar Global Mining 1
2 A History of Progress 1925: Holt & Best companies merge into Caterpillar Tractor Co : Rapid global expansion 2001: Joined World Business Council for Sustainable Development 1925 $13.8 Million 1930 $45.4 Million 1940 $73.1 Million 1950 $337.3 Million 1960 $716 Million 1970 $2.1 Billion 1980* $8.6 Billion 1990 $11.4 Billion 2000 $20.2 Billion 2010 $42.5 Billion 2011 $60.1 Billion 1931: First diesel track-type tractor 1942: Cat machines serve in World War II 1986: Factory modernization 2011: Acquired Bucyrus International, Inc. * In 1978, the company began reporting Sales & Revenues 2
3 A Global Reach Global reach and presence is unmatched in the industry Serve customers in more than 180 countries around the globe More than half of our sales are outside the United States Manufacturing, marketing, logistics, service, R&D and related facilities along with our dealer locations total more than 500 locations worldwide Dealers 188 worldwide with more than 126,000 employees Independent, locally owned Key competitive advantage 3
4 Original Caterpillar Tractor Company Office (circa 1935) 4
5 CAT and OSIsoft, a lot in common 5
6 A Broad Range of Products and Industries Cat equipment more than 3 million pieces globally is at work for our customers on highways, rail lines, oceans and rivers, in forests, quarries, mine sites and oil fields. 6
7 The Next Great Chapter in Mining 7
8 Mining Equipment Management Availability Component Life Rebuild Cost Maintenance & Repair Process + + = Application Changeable Non-Changeable Component Life Management Component Renewal Product Quality & Reliability Cost / Hr Cost / Ton MARC Management Ø Preventative Maintenance Ø Condition Monitoring Ø Planning & Scheduling Ø Repair Mgmt Ø Component Mgmt Ø Backlog Mgmt Ø Parts Mgmt Ø Training Ø Performance Evaluation Ø Continuous Improvement Ø Mine Location Ø Pit Design Ø Haul Road Conditions Ø Truck Loading Ø Component History Mgmt Ø Repair Management Ø Component Database Mgmt Ø Rebuild Mgmt (CRC) Ø Component Performance Rpt Ø Salvage Mgmt (Shop) - Product Groups - Regions / Dealers Ø Unique Component Identifier Ø Statistical Life Projection Ø Assist CPI Find-it prioritization Ø Designed Life Ø CPI Issues Fix Ø Serviceability Ø Parts Commonality Ø Failure Reporting Ø Market Strategy Ø Rate Development Ø Risk Analysis & Quantification Ø Strategy Development & Implementation Ø Financial Management Common Processes Continuous Improvement Global Consistency Best Practices Common Metrics 8
9 Common Definition the proactive process of evaluating equipment and application date inputs in order to provide maintenance, component replacement, application and repair recommendations that help customers lower owning and operating costs, improve availability and reduce warranty costs. Dealers must analyze electronic data, fluid analysis results, inspection results, equipment history and site analysis into value-added recommendations for customers. 9
10 Condition Monitoring Past Present Capability ceiling From informa*on overload. To ac*onable intelligence 10
11 Machine Compared to a Standard Identify emerging failures based on standard and engineering limit excursions and rates of change in data sources exceeding nominal values Upper Limit Actual ROC UCL Mean Lower Limit LCL Engineering Limits Rate Of Change (ROC) Statistical Quality Control (SQC) Events # of occurrences in time window t Event Analyzer Exceptions Data Used Trends Fluid analysis raw data Events (frequency of events) Real time streaming data (if available) 11
12 Analy3cal Models Air Filter Restric3on HI/Low Results /No3fica3on Boost Pressure vs Rate Of Change Trends Data Exhaust Split Sta3s3cal Quality Control Modeling Events 12
13 An Overview of the Equipment 13
14 Value of Condition Monitoring Benefits for customers. Benefits for Caterpillar and Dealers Information vs. data Differentiation in the marketplace Less labor to identify repair Long-term partnerships with our customers recommendations Improved understanding of equipment Better equipment utilization applications Reduced unit operating costs 14
15 A Winning Partnership Technology + + Caterpillar Product Knowledge Cat Dealer Service Excellence The Right Tools to Manage Data and Rapidly Turn It Into Ac*on 15
16 Tim Siekmann Caterpillar Inc. - Global Mining Office: Siekmann_Tim_W@cat.com Brought to you by
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