Smart Services/PreVail - Remote Health Management

phmsociety 2013

By:
Anubhaw Bhushan
Program Manager - Remote Health Management

Who Are We?

Lifecycle Management
2 29 October 2013 ES-41213 Improvement Project

How Big?

Integrating Equipment, Information and Service

World Class
Performance

Data

Information

Direction

Results

Smart
Services

Life Cycle
Management

Operational
Excellence

Knowledge
Generation and
Continuous
Improvement

Smart Service
Integration

Smart Service
Delivery

Case Management,
Escalation and Resolution

Work Order Generation

OEE

Issue Aggregation w/
Supporting Data

Supply Chain
Optimization

Real Time
All the Time

Sub-System Specific
Odometers

As Operated Tailored
Training

World Class Performance

Through Strategic
Partnerships

Best Practice

Machine Inspections

Mastering Lean Mining

Methods

2016
Integrated Solutions

Game Changing Service Offering

Continuous Focus on Improving Operations

2013
Smart Services

2012
Data to Knowledge

2010
PreVail

Core Joy Global Services

Service Centres back to OE

Repairs
Local Field Service
Product training
Parts Warehousing
Technical Resources
Asset Revitalizations

Enabled Machine Wi-Fi

Communication
Data Visualization
Real- Time Monitoring
Remote Diagnostics
Integrated Schematics & Parts
Books
Historical Analysis

Condition Based
Equipment Monitoring
Operator Scorecards
Monthly
Reports/Comparisons
Cost Avoidance
Calculations
Component Tracking
System
Workflow Engines-Issue
Resolution

-CONFIDENTIAL-

Smart solutions
global network
Integrated work orders
- maintenance
- parts orders
Service Life Management

Global Benchmarking
Performance Analysis (OEE)
Integrated Monitoring Centers
Productivity Analysis & Reporting
Customer Portal - Visibility
-Part Locations & Orders
- Equipment and system performance
Global network
- Monitoring all equipment
Dispatch people and product
Integration with customer monitoring
centers

Align to Global Services Network

Smart Services Globally - Lead with Service
Pittsburgh Future

Kuzbass Q4 2013

Pinxton

Mt. Vernon
Baotou - Q2 2012

Joy locations
LaNegra
P&H locations
LeTourneau locations
Joy Global Facilities
JOYG Headquarters

Witbank
Innovation Campus - Q3 2012

Leverage regional centers to support us 24/7 around the globe

Hunter Valley - Q3 2013

PreVail Journey/Architecture/Value Offering

The Journey of PreVail

PreVail as a
Subscription
Underground

Machine Data

Maintenance

Custom Dashboards
shovel production data
Batch based rules

2009

FCT, LWS, Drill, NonCenturion, JNA

machines
Expert Rules

2010

20

Shovels

Balance of Fleet
100s of Expert Rules
100s of machines

Expanded
Fleet

Production

Shovels

Scalability

Underground
Maintenance &
Prognostics
First Continuous Miner

Maintenance Product
for Shovels on the
Centurion Platform

PreVail enabling
Smart Service

Value to the Customer

PreVail as a
Product

2011

40

Shovels

& Miners

2012

80

Total
Fleet

2013

130

Total
Fleet

PreVail Architecture

PreVail Value Addition

Milwaukee
Analysts

Field
Technical
Resources

PreVails
Value
Added

Cost
Avoidance /
Opportunity
Costs

Customer
Resources

10

Power of Data

Machines Behavior Hoist Over speed Event

Time Stamp
13:29:52.646:
13:29:54.033:
13:29:54.156:
13:29:55.265
13:29:57.632:

Events
Operator ref went down to 0 RPM, the lowering speed continued to increase
Armature and Field Currents at current limit
Load continued to accelerate to -1094 RPM, maximum motion torque failed to hold
the dipper & contents
Hoist over speed fault logged, brakes automatically applied
Dipper fell another 5.7 meters before its motion was halted

Machines Behavior Contd..

Power of Data Trending, Computing, to aid in the explanation of
Machines behavior down to milliseconds interval.

Machine Health Analysis - Voltage Feed

Scenario 1

PreVail Analysis

CBEM Augmentation

Competitive Benefit

Mains Voltage
Signature-Weak
power distribution

Trending of mains voltage

trips alarms correlation used
to detect the possible issue
causing downtime

A model built on the historical

data and has triggered
numerous true positive alerts,
leading one of them into a
case study

Faster RCA and corrective action

leading to shorten the trail cable length
and stabilize the power feed
Use of Expert domain knowledge and
predictive modeling

Part Malfunction Detection

Scenario 3

PreVail Analysis

CBEM Augmentation

Competitive Benefit

AirScrub
PlePressure

Trending of the relevant tag and

comparative analysis with its
behavior on other machines
helped identified the issue

A model built on the field

investigation, triggered a true
positive alert and helped
identified a leaky air regulator
feeding the manifold

Leveraged the globally deployed shovel

fleet performance to distinguish between
normal vs. abnormal behavior
Expert domain knowledge used to
quickly direct the field reps to take
corrective action.

Results - Operational Excellence

1.80

Brakes related Faults/Warnings

89%

1.60

Lube & Air related Faults/Warnings

74%

SIIR

BJIR

MSIR

1.40

152

1.20
1.00

113

0.80
0.60
54

0.40

47

0.20

18

0.00
1Q-2012

2Q-2012

3Q-2012

4Q-2012

1Q-2013

2Q-2013

September

October

12
November

16
12
December

Capitalized on Operating Practices Refinement

Opportunities

Maintenance Optimization -Faults Reduction Over Last

Two Quarters of 2012

CUSTOMER ENGAGEMENT MODEL

Prescriptive & Predictive Data Analysis Proactive

Data Analysts + CBEM Rules
Machine Knowledge Access to SMEs & Engineers
Notification/Reporting 35 FSNs, 48 Weekly
Trackers, 12 Monthly Reports
Recommendations/Corrective Action Closing the
Loop with the Mine Site and Field Champions
SIIR = Swing Impacts Index Ratio, BJIR = Boom Jacks Index
Ratio, MSIR = Motor Stalls Index Ration, Index Ratio =
Counts per Operating Hour, CBEM = Condition Based
Equipment Monitoring

100
90
80

350

70

250

60

200

Rate

2,000

300

50
40

150

30

100

20

Rate Increase TPH

Hours Saved

Results - Productivity Improvements

100

80

1,500

60
1,000
40
500

20

50

10
0

AFC
Cases

LWS
Hours

PRS
TPH Increase

Completed 180 cases

Saved 168 Hours
Rate increase 309 Tonnes per Hour

Value in Tonnes/Year = 1,85 M Tonnes

1,85 MTons * $150/Ton = $277 M
Note: Value calculated on 100Hrs per week at 1500Tons per Hour

Mine
Cutting
Average Weekly Hrs and Rate by Month Hrs

Average Weekly Rate

Average Weekly Hrs

0
Feb-12 Apr-12 Jun-12 Aug-12 Oct-12 Dec-12 Feb-13 Apr-13

Avg Weekly
Tonnes
(000)

Mine
Average Weekly Tonnes by Month

200
150
100
50

Average Weekly Tonnes

0
Feb-12 Apr-12 Jun-12 Aug-12 Oct-12 Dec-12 Feb-13 Apr-13

Thank You!