Professional Documents
Culture Documents
de Equipo Pesado
MIN268
Profesor :Augusto Ayesta C
Reliability MTBF
100
100
7
M TB F
Av ailability
Ut li izat ion
60
Targ et
80
MTBF (Hours)
MT T R
Target
Target
80
70
MTTR (hours)
90
60
40
3
20
50
40
January
Marc h
February
May
April
July
June
0
January
M arch
M ay
Jul y
Sept ember November
February
A pri l
June
A ugust
Oct ober
December
Sept ember
Nov ember
August
Oc tober
December
1
January
March
M ay
July
Sep temb er Novem ber
February
April
June
Aug ust
O ctob er
Dece mber
Maintenance Ratio MR
0 .6
MR
Target
0 .5
0 .4
0 .3
Av a ila bility
Ut ilizat ion
MTBF (Hours)
June
S eptem ber
Novem ber
August
October
December
Jul y
70
60
MTTR
Target
MTTR w/o Delay s
40
May
Apr il
Ju ly
J un e
0
January
March
February
April
Se pt emb er
No v emb er
Aug us t
Oc to be r
D ec emb er
May
July
June
Sept ember
November
August
Oc tober
December
1
January
Marc h
February
April
May
July
J une
Sept ember
Nov em ber
Augus t
Oc tober
December
100
0.6
MR
Target
0.5
0.4
0.3
0.2
0.1
0
January
March
February
April
May
July
June
Sept ember
Novem ber
August
October
Decem ber
Disponibilidad %
60
20
50
40
Ja nu ar y
Mar ch
Fe br ua ry
80
Tar ge t
80
M ay
MTTR (hours)
90
0 .1
0
January
March
Febru ary
A pri l
100
1 00
0 .2
90
80
70
60
25
45
65
85
105
125
142
162
182
La diferencia........
Operaci
Operacin
Disponibilidad
A:
B:
C:
D:
92
92
88
95
La diferencia........
Evale la Gestin de las Gerencias de Mantenimiento de dos operaciones A y B
Op. A
Enero
Disponibilidad Mecanica
MTBS
MTTR
Precision de Servicio
% programados
MTBS despues de PM
Relacin de Mantenimiento
% Servicio almacn de repuestos
Backlog ejecutados por PM
88.24%
30
4
70
60
40
0.2
80
5
Diciembre
93.02%
80
6
90
70
90
0.6
95
6
Op B
Enero
86.96%
20
3
70
60
30
0.2
80
3
Diciembre
93.10%
27
2
50
50
20
0.2
90
0
Objetivos
= P x U / C
Programar
&
Reparar
Repara
Adan & Eva
Monitorear,
Predecir,
Programar,
& Reparar
WW II
1980s
Evolucin
Tipo de Gestin vs Confiabilidad
/ PMO
Gerencia Lider
Planeamiento Estrat
Estratgico
Sistema Integrado de Informaci
Informacin
Gerencia de la Persona
Responsabilidad , Autoridad
Desarrollo y Reconocimiento
EMS
Gestin de la Aplicacin
Deje a la Aplicacin guiar su
Estrategia de Mantenimiento
Produccin
Actual versus Target Ton/day
200
Tons/day.Target
Tons/day.Actual
Ore. Actual
Tons
Thousands
150
Ore. Target
100
50
0
January
February
March
April
May
June
July
August
September
October
November
December
Analysis
Definiciondel Camino
de Acarreo
Area de Carga
Dump
Camino
Principal
Veloc.
Suelo:
-RR
-% Pendiente
GVW=EVW + Payload*
Curvas de Capacidad de
Frenado (Retarding) El
principio.........
Observacin en campo
Sistemas en la Cabina,
data del VIMS
Nueva tecnologa (CAES)
Sistema Dispatch
Reportes de Produccion
others.
Recoleccin de
Datos
Modo de
Operacion
Viaje
Parada
Carga
Descarga
Solo Vims
Fuente de datos
TPMS o VIMS
Rack de Maquina
Pitch de Maquina
Load Bias
Etapa de Carga
Del.Derecho
Del.Izquierdo
Post.Izquierd
Post.Derecho
16000
14000
12000
10000
8000
6000
4000
2000
LEFT REAR
20000
Giros
18000
14000
12000
10000
8000
6000
4000
2000
0
27
99
175
243
310
380
456
530
589
657
733
809
885
945
998
1056
1094
1105
1127
1182
1258
1306
1314
1327
20,000
18,000
16,000
14,000
12,000
10,000
Management Line
8,000
COMPOSITE STRUT PRESSURES (kPa)
6,000
4,000
2,000
0
-2,000
-4,000
-6,000
-8,000
Management Line
-10,000
-12,000
-14,000
-16,000
-18,000
-20,000
37
107
186
248
325
426
540
685
802
884
946
1021
1091
1143
1183
1223
1268
1334
1420
1496
1576
1613
1629
1635
20,000
18,000
16,000
14,000
12,000
Management Line
10,000
COMPOSITE STRUT PRESSURES (kPa)
16000
8,000
6,000
4,000
2,000
0
-2,000
-4,000
-6,000
-8,000
Management Line
-10,000
-12,000
-14,000
-16,000
-18,000
-20,000
1
93
201
319
432
552
660
768
876
986
1096
1206
1315
1423
1532
1640
1749
1832
1934
2043
2177
2369
2531
2571
2605
10
EMS
Gestin del Sistema de
Mantenimiento por
Indicadores
Benchmarking Medidas de Rendimiento....
...Kpi (Key Performance indicators)
La diferencia........
Mina
Disponibilidad
A:
B:
C:
D:
92
92
88
95
11
12
Mquina
Operativa
Reportes de
Produccin
Disponibilidad
Utilizacin
Detencin
Imprevista
Inspeccin
Operador
Informacin Diaria
Operaciones
Produccin
Hrs Operacionales
Campo
Inspeccin
Inspeccin Diaria
Mantenimiento
Planeacin
No Crtico
Tendencias,
Pruebas
Rendimiento
Backlog
Reuniones
Coordinacin
Semanales
Programacin
Prod./Mant.
Control Componentes
OK
Resultado
Taller
Actualizacin
Historia Equipos
Campo
Repara
Campo
Resultado
Disponibilidad,
Entrega
Reportes
Administracin
Equipos
Crtico
Administracin de Problemas
Identificacin de
Problemas & Plan de
Accin
Partes
Orden Trabajo
Detiene
la
Mquina
Realiza Reparaciones
Programadas y No
Programadas
Analiza
Informacin
Cierra OT
No Cumple
Centros Reparacin
Control
Calidad
Cumple
El Sistema de Mantenimiento
Explicacin detallada
13
Benchmarks
operaciones.. Administracion de cargas, demoras,
tiempos de carga, tiempo de exchange , produccion,
costo por tonelada, etc..
14
EQUIPMENT
METRICS
1
CALCULATION
MANAGEMENT
WHAT IS NEEDED TO
Records : - Service History
(Hours/SMU/Work Done)
- Components Control
Operation Hours
Availability
A=
Utilization
U=
Operation Hours
x 100 (%)
x 100 (%)
Programmed Hours
4
MTBS
MTBS =
MTTR
MTTR=
MR
Maintenence Ratio
% SCHEDULED WORK
Repair Hours
Ns. of Failures or Shutdowns
Operation Hours
Ns. of Failures or Shutdowns
MR=
SW=
Operation Hours
Ns. of scheduled repairs
Ns. of Failures or Shutdowns
x 100 (%)
10
SERVICE ACCURACY
SHUTDOWNS PER
SYST. / COMPONENTS
Maintenance Man-Hours
- SMU
Machine History
SA=
SHP - SHE
SHP
x 100 (%)
Age of Equipment
YES
92 % nuevos
88 % viejos
Equipment Use.
Labor/Parts, Burden estimation
90 %
80 hrs new
60 hrs old
Reliability
A=
MTBS
x 100 (%)
MTBS + MTTR
Turnaround
(Effectiveness &
Response of Repairs)
Effort invested
Quality of repairs/labor
0.2 new
0.3 old
Who is in control !
The Maintenance Organization or
the Machine
80 %
YES
Backlogs age
Quantity
Estimated hours to perform
Backlogs
3 - 6 hrs
11
BACKLOGS
CONTROL
12
RECORD KEEPING
13
TRENDS
Consummables control
S.O.S. - Results Interpretation
Tests / VIMS Results . . .
Prognostics
Component Life Management
Problem Management
YES
Within 10 %
YES
100 %
YES
15
Benchmark: SI (subjetivo)
registros tiles & orientados a la accin
Precisos/ Completos/ a tiempo
collecione datos cada turno; registre diario; analize
mensualmente;monitoree/ tendencias en toda la vida
del equipo.
16
Horas Operacin
Horas Operacin+Hrs downtime
3.) Utilizacion:
Utilizacion (%) = Horas Operacion
Horas disponibles
17
Horas Paralizacin
numero paralizaciones
18
Porqu MTBS?
comprarse >>> mano obra en
exceso,facilidades , repuestos, etc. = bajo MTTR.
La disponibilidad puede
MTBS
Alto MTBS =
19
Reliability CONFIABILIDAD
R=e-T/MTBF
Donde T = intervalo de tiempo
MTBF :tiempo medio entre fallas
MTBS tiempo medio entre paralizaciones (Programadas y
No Programadas)
MTBS= Horas de Operacion/# de Paralizaciones
MTTR=Horas de Paralizacion/# de Paralizaciones
% Disp.Mecanica=MTBS/MTBS+MTTR
100%
100%
90%
90%
80%
80%
70%
70%
60%
60%
50%
50%
40%
40%
30%
30%
20%
20%
10%
10%
0%
0
25
50
75
Reliability - (%)
Availability - (% )
R=e-T/MTBF
0%
100
MTBS - (hours)
20
MTBS
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
50
"t"
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
"- t/mtbs"
-1.00
-0.50
-0.33
-0.25
-0.20
-0.17
-0.14
-0.13
-0.11
-0.10
-0.09
-0.08
-0.08
-0.07
-0.07
Prob.No Falla
Prob.Falla
"e ^-t/mtbs" "1-e^-t/mtbs"
36.79%
63.21%
60.65%
39.35%
71.65%
28.35%
77.88%
22.12%
81.87%
18.13%
84.65%
15.35%
86.69%
13.31%
88.25%
11.75%
89.48%
10.52%
90.48%
9.52%
91.31%
8.69%
92.00%
8.00%
92.60%
7.40%
93.11%
6.89%
93.55%
6.45%
Prob Falla
Camiones
32
20
14
11
9
8
7
6
5
5
4
4
4
3
3
MTTR
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
Disp.Mec
80.00%
88.89%
92.31%
94.12%
95.24%
96.00%
96.55%
96.97%
97.30%
97.56%
97.78%
97.96%
98.11%
98.25%
98.36%
AAC/2004
MTBS
Edad
Diseo
Mas Complejo
Aplicacin
& Operacin
Mas Severa
21
Availability - (%)
90
MTBS
80
60
40
20
85
80
75
70
65
60
55
50
45
40
9 10 11 12 13 14 15 16 17 18 19 20
MTTR - (hours)
Availability - (%)
MTTR
90
2 hrs
3 hrs
4 hrs
5 hrs
6 hrs
7 hrs
8 hrs
9 hrs
85
80
75
70
65
60
5
15
25
35
45
55
65
75
85
95 105 115 125 135 145 155 165 175 185 195
MTBS - (hours)
22
Availability %
85%
86%
87%
MTTR - (hours)
15
88%
89%
target operating range
90%
10
91%
92%
93%
94%
MTTR
3 - 6 hrs
95%
MTBS
60 - 80 hrs
10
20
30
40
50
60
70
80
90
100
MTBS - (hours)
Descripcin
Hydraulic System
Tires & Rims
Lights
Wait on Mechanic
Wheel Brake System
Oper. Compartment
Engine
Mirrors
Aux. Equipment
PM
Wheel System
Cooling System
Suspension
Horas
Horas Operacin= 14769
Paralizacin # Paralizac. MTTR MTBS
824.44
130
6.34
114
298.58
92
3.25
161
70.26
67
1.05
220
78.61
48
1.64
308
328.28
46
7.14
321
75.75
43
1.76
343
248.68
41
6.07
360
15.04
37
0.41
399
43.51
36
1.21
410
1553.88
32
48.56
462
595.34
32
18.60
462
262.49
29
9.05
509
39.83
29
1.37
509
23
10 0
100
M TBS
A vailab ility
U tilization
90
80
M TTR
Targ et
Target
70
60
MTTR (hours)
MTBS (hours)
Ta rg et
M TTR w/o D e la ys
80
60
40
20
50
40
Ja nuary
March
May
Ju ly
Se ptem berN ovem ber
F ebru ary
A pril
June
A ugust
O cto ber D ecem ber
5
4
3
2
0
Ja n ua ry M a rch
Ma y
July S ep tem beNr ove m be r
Fe bru ary
Ap ril
Ju ne
A ug us t O c to b er De ce m b er
1
Ja nu ary M a rc h
M ay
July S ep tem b er
No ve m be r
Fe bru ary Ap ril
Ju ne
Au g ust O ctob e r De ce m b er
Majo r D rivers
M aintenan ce R atio M R
0.6
MR
Labor/Op. hours
0.5
Target
0.4
0.3
0.2
M ajo r Actio ns
0.1
0
January
March
May
July
S eptember N ovember
February
A pril
June
A ugust
O ctober Decem ber
G E N E R A L P E R FO R M A N C E M ET R IC S
24
Relacion de Mantenimiento
Benchmark (OHTs): = .20 to .30 (directo)
.50 (total)
directo MR incluye la M.O.de todas las OT,
total MR incluye horas de OT ms administracin ,staff,
supervisin y horas muertas,
incluye R&I de componentes; excluye reparcin de componentes &
neumticos ,
puede ser una buena herramienta para presupuesto de mano de
obra,
indicacion deo la eficiencia de la fuerza laboral ,
report monthly (by fleet); monitor/ trend over 12 month interval.
MR
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
20
40
60
80
MTBS - (hours)
25
26
Service Accuracy
Service Accuracy
100
450
S ervice Accuracy
Intervals (hours)
Upper L imit
350
Se rvices
300
250
200
Lower L imit
400
Target
80
60
40
20
150
100
01/03/96
03/18/96
02/09/96
05/18/96
0 4/18/96
07/27/96
06/30/96
0
January
M arch
M ay
July
Septem ber Novem ber
February
April
June
August
O ctober Decem ber
10/24/96
09/07/96
S ervices Perform ed
Major Drivers
% Scheduled Shutdowns
100
% Scheduled Shutdowns
% Scheduled
Target
80
60
40
Major Actions
20
January
March
May
July
Septem ber November
February
April
June
August
October December
27
February March
0
1st Priority
T.Converters
1st Priority
Transmissions
1st Priority
Differentials
1st Priority
Final Drives
1st Priority
April
May
June
July
August
Eng 7
0
TC8
xmsn 7
Diff 8
0
Man Hours
Downtime
6
FD11/FD12
760
380
72
36
0
0
32
16
376
188
144
72
216
108
224
112
0
0
96
48
0
0
112
56
0.00
0.00
0.16
0.19
1.87
2.13
0.74
0.84
1.08
1.22
1.12
1.27
0.00
0.00
0.48
0.54
0.00
0.00
0.56
0.63
3.78
4.30
0.40
0.45
116
151
29
58
75
0
0.29
0.33
0.00
0.00
Note:
90.00 %
79.12 %
Situation Analysis
C O M PO N EN T R EPLA C EM EN T PR O G R A M
Transm ission s
D ifferen tials
H ours
Thousands
0
10
Hours
Thousands
15
xm sn 1
D iff1
xm sn 2
D iff2
xm sn 3
D iff3
xm sn 4
D iff4
xm sn 5
D iff5
xm sn 6
D iff6
xm sn 7
D iff7
xm sn 8
D iff8
xm sn 9
D iff9
xm sn10
D iff10
xm sn11
Diff11
xm sn12
D iff12
xm sn13
D iff13
xm sn14
D iff14
xm sn15
10
15
D iff15
Target
Target
28
29
Last 6 M onths
35
En gin e
XMSN /TC
D iff/Fina ls
Electrical
Fram e
H ydraulic
Tires
PM s
O thers
30
3.0%
20.0%
8.0%
4.0%
5.0%
13.0%
E ngine
X MSN/TC
Dif/Finals
E lectrical
Frame
Hydraulic
Tires
P Ms
O thers
25
20
15
10
5
31.0%
July
Au gust
Septem be r
O cto ber
Nove m ber
D ecem b er
L ast 6 M on ths
17 .0%
10.0%
7.0%
6.0%
2.0%
4.0 %
23.0%
Engine
XM SN /TC
D if/Finals
Electrical
Fram e
H ydraulic
Tires
PM s
Others
60
100
50
En gin e
XM SN/TC
80
Diff/Finals
40
60
30
40
20
Availability (%)
7.0%
% of Total Cost
9.0%
F ra m e
Tires
PMs
20
10
Electrical
Hyd ra ulic
17.0%
Others
14.0%
July
A ugust
Availabilty
Goal
Influence on Reliability
Last 6 Months
30
40
Engine
5.0%
9.0%
4.0%
4.0%
8.0%
25.0%
Engine
XMSN/TC
Dif/Finals
Electrical
Fram e
Hydraulic
Tires
PMs
O thers
XMSN/T C
25
30
20
15
20
10
10
5
7.0%
27.0%
Diff/F inals
Electrical
Fram e
Hydraulic
Tires
PMs
Othe rs
11.0%
MT BF Trend
July
August
September
October
November
December
Influence on Turnaround
Last 6 Months
40
8.0%
12 .0%
1 0.0%
1.0%
28 .0%
17.0%
En gin e
XMS N/TC
Dif/Fina ls
Electrica l
Fram e
Hydraulic
Tires
PMs
Others
6
30
5
4
20
3
2
10
XMSN/TC
7.0%
Engine
7.0%
Diff/Finals
Electrical
Fram e
Hydraulic
Tires
PMs
Others
MTTR Trend
10 .0 %
July
August
S eptem ber
October
N ovem ber
D ecem ber
30
D elay Causes
Delays Downtime
14
14
12
12
10
10
13.5%
Tools
21.6%
Tools
Aux. E q.
Labor
8.1%
21.6%
Com ponents
Facilities
8.1%
Delay Hours
P arts
Facilities
Parts
Com ponents
Labor
Aux. Equip.
Infl. on Availability
27.0%
July
August
Septem ber
October
M onths
Novem ber
Decem ber
20
15
Situation Analysis
10
0
January
March
Fe brua ry
April
May
July
June
Total M TTR
Hours
5
4
3
2
1
0
January
March
February
April
May
July
June
31
B acklogs Q uantity
400
Q uantity
100
10 00
Executed
8 00
200
100
80
Percentage %
Downtime (hrs)
300
Quantity of BL
90
6 00
4 00
70
60
50
2 00
40
0
April
June
M ay
August
July
O ctuber
Septem ber
D ecem ber
N oviem ber
0
A pril
Ju ne
Ma y
July
A ug ust
Octo be r
D ecem b er
Se ptem be r
Novem b er
Backlog Status
30
April
June
May
August
July
O ctober
September
December
N ov ember
0.590.77
80
3.24
1.47
Percentage %
2.4
60
2.44
0.93
40
1.35
3.04
20
1.03
0
April
June
M ay
August
July
O ctober
Septem ber
D ecem ber
N ovem ber
4.11
3.04
E ngine
E lectrical
Transmission
Hydraulics
S tee ring
A ir S ys.
PM
Tires
Diffe rential
Final Drives
B rakes
S uspensions
F.W hee ls
Fire S up.
A ccid ents
A ir/Cond
0.65
32
PM Effectiveness
70
20
Overall MTBF
60
MTBF (Hours)
MTBF Target
40
30
20
MTBF after PM
50
15
10
10
0
January
March
May
July
September November
February
April
June
August
October Decem ber
0
January
March
May
July
September November
February
April
June
August
October December
PM Efficiency
PM250
14
Situation Analysis
PM500
12
PM1000
Hours
10
PM2000
8
6
4
Target
2
0
January
March
May
July
Septem ber N ovem ber
February
April
June
August
October Decem ber
PM EXECUTION
33
Analisis - Segmentacion
Complejidad de Maquina = Complejidad de Sistemas & Data...
Codigo de Componentes
All Data
Complex
Engine System
Air
Induction
Fuel Sys.
Lube Sys.
Starting
Drivetrain
Chassis
Cooling-Engine
Hydraulics
GET
Etc...
Trabajador
Turno
Flota
Aplicacion
34
Descripcin
Hydraulic System
Tires & Rims
Lights
Wait on Mechanic
Wheel Brake System
Oper. Compartment
Engine
Mirrors
Aux. Equipment
PM
Wheel System
Cooling System
Suspension
Horas
Horas Operacin= 14769
Paralizacin # Paralizac. MTTR MTBS
824.44
130
6.34
114
298.58
92
3.25
161
70.26
67
1.05
220
78.61
48
1.64
308
328.28
46
7.14
321
75.75
43
1.76
343
248.68
41
6.07
360
15.04
37
0.41
399
43.51
36
1.21
410
1553.88
32
48.56
462
595.34
32
18.60
462
262.49
29
9.05
509
39.83
29
1.37
509
35
13.) Tendencias :
Benchmark: (subjectivo)
100% de los parmetros de monitoreo de condiciones son
registrados y su tendencia es analizada,
como resultado del anlisis se toman decisiones y acciones
Torq ue Stall R PM
B low B y
Engine Eng7
E ngine E ng7
Engine Eng7
1 8 00
2 00
44 0
42 0
1 80
1 7 50
cu feet/hr
RPM
Lts/hr
40 0
1 60
1 7 00
1 40
1 20
38 0
36 0
34 0
1 6 50
32 0
1 00
1000
3000
5000
7000 9000
H ours
11000 13000
1 6 00
10 00
30 00
30 0
11 00 0 1 30 00
1000
3000
1300 0
110 00
1 30 00
40
ppm of xx
kPa
0 .05
11000
50
450
0.1
7000
9000
Ho urs
E ngine E ng7
500
0 .15
5000
SO S R esults
E ngine Eng7
Eng in e En g7
0.2
Lts/hr
7 00 0
90 00
Hours
Oil Pressure
O il C onsum ption
5 00 0
400
30
20
350
10
1000
3000
5000
7000
9000
H ours
11000
13000
300
1000
3000
5000
7000
9000
Ho urs
11000
13000
10 00
30 00
50 00
70 00
90 00
Hours
PCR date:
January 199x
E valuation R esults
R ecom m endation
C O M PO N EN T C O N D IT IO N M O N ITO R IN G
36
MTBF
Fleet No. xx
80
Monthly MTB F
MTBF (Hours)
70
Roll. 12 M TBF
60
50
40
30
Fleet Information
20
10
1993
1994
1995
1996
Manufacturer
Truck Model
Acquisition Year
Num ber of Trucks
1997
:
:
:
:
XYZ
AAA
1993
8
M aintenance Cost/hr
Fleet No. xx
Situation Analysis
35
Monthly Cost
Rolling 12
30
Cost US$/hr
25
20
15
10
5
0
1993
1994
1995
1996
1997
La diferencia........
Operaci
Operacin
Disponibilidad
92
92
88
95
MTBS
70
23
80
20
MTTR
37
La diferencia........
Evale la Gestin de las Gerencias de Mantenimiento de dos operaciones A y B
Op. A
Enero
Disponibilidad Mecanica
MTBS
MTTR
Precision de Servicio
% programados
MTBS despues de PM
Relacin de Mantenimiento
% Servicio almacn de repuestos
Backlog ejecutados por PM
88.24%
30
4
70
60
40
0.2
80
5
Diciembre
93.02%
80
6
90
70
90
0.6
95
6
Op B
Enero
86.96%
20
3
70
60
30
0.2
80
3
Diciembre
93.10%
27
2
50
50
20
0.2
90
0
38