05 Equipment Maintenance

7/28/2019 05 Equipment Maintenance

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Equipment

Maintenance


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Maintenance

Equipment Maintenance Programs (EMP)should include:

Complete list of maintenance required foreach piece of equipment and when due

Means of tracking equipment hours

Means of performing each service

Complete history for each piece of equipment(hours, services, fuel use, etc..)


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Maintenance (cont)

Dust

High Temperatures

Blowing Garbage Heavy Loads & Uphill Pushing

Walk-Around Inspection


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Equipment Care &

Maintenance

With proper maintenance, the machines atyour landfill will last longer, run cheaperand have fewer unexpected breakdowns

Here are some considerations in regard toEquipment Care and Maintenance


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Equipment Maintenance

Importance of Good Maintenance

Prioritizing your Maintenance Effort

Operators Responsibility Walk-around Inspections

Pay Attention while Operating

Recordkeeping Pre-planning for Optimum Efficiency


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Walk-Around Inspection

Blade/Cutting

Edges

Compactor Tips

Hydraulic Lines

Hydraulic Cylinders

Articulation Joint

Steps/Handholds

Engine

Compartment Cooling System

Differentials

Final Drive

Transmission

Cab & Glass Clean

Master Link Tight

Air Lines Intact

Backup Alarm

Working Tires Properly

Inflated

Seat Belt

Undercarriage OK

Air Intake SystemOK

Check for Fuel Leaks

Guards/Belly Pan

Trunnion Caps


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Check for Loose or Missing

Cutting Edges


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Check Tire Pressure

Look for Damage


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Do the Gauges Work?

Are They Clean Enough to

See?


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Keep Air Filter Clean


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Record Fuel Use

Avoid Spillage


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Check Teeth, Center Pin,

Steps, Hydraulic Lines, etc.


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Is Your Machine Overheating?

Check Those Side-screens.


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Black Smoke? Loss of

Power?

Check the Intake


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Watch for Waste Riding up on

Wheels or Tracks


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Did You Know?

The Lifetime costs for a machine maybe 3-5 times the purchase price.

Dont get hung up on Purchase Price!!


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Equipment Cost

Contrary to popular belief, equipment costdoes not equal purchase price.

It equals:

Price

Operating Cost

Productivity

Uptime


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Considerations when

Purchasing a Machine

Equip Cost = Equip Price Equipment cost =

Price + operating cost

+ productivity

+ up-time

Lifetime costs forequipment ~ 3-5 timesthe purchase price.


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What is Equipment Cost?

Owning Costs

Bank

Interest

Insurance Taxes

Consider the TimeValue of Money

Operating Costs

Fuel

Labor

Repairs Maintenance

G.E.T.

Special Items

tire chains

attachments


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Owning and Operating (O&O)

Costs

Owning costs

purchase cost

interest

insurance taxes

Operating costs fuel

lube oils

filters and grease

tires

undercarriage

repair reserve

special wear items

productivity*

downtime*


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Owning & Operating Costs

Definitions

Owning Costs (fixed costs)

Operating Costs (variable costs)

How to Calculate

Considerations when Purchasing aMachine

Establishing Limits for Repair Costs


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Definitions Owning Costs

Principle

Interest

Insurance

Taxes

Capitalized Repairs

Operating Costs

Labor

Fuel

Repairs

Cutting Edges

Services


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Calculating O & O CostsMachine Designation: _____________________

Estimated Ownership Period (years):___Ownership Usage (total hours):___

OWNING COSTS

1.a. Delivered Price (including attachments): $____________

b. Less Tire Replacement Cost if Desired: $_____________

c. Delivered Price Less Tires: $_____________

2. Less Residual Value at Replacement: $_____________3.a. Value to be Recovered Through Work: $_____________

b. Cost Per Hour (value / hours): $_____________

4. Interest Costs: $_____________

5. Insurance Costs: $_____________

6. Property Costs: $_____________

7. Total Hourly Owning Cost (add lines 3b,4,5, and 6): $_____________


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Calculating O & O Costs

OPERATING COSTS

8. Fuel: $_____________

9. Lube, Oil, Filters and Grease: $_____________

10. a. Tires (Replacement Cost / Life): $_____________

b. Undercarriage: $_____________

11. Repair Reserve: $_____________

12. Special Wear Items: $_____________

13. Total Hourly Operating cost (add lines 8,9,10a (or 10b), 11 and 12): $______

14. Machine Owning plus Operating (add lines 7 and 13): $_____________

15. Operators Hourly Wage (include fringes): $_____________

16. TOTAL OWNING AND OPERATING COST: $_____________


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Breakdown of Equipment

Cost

Heres a typical

breakdown ofequipment costs.

Dont try to savemoney by cutting

servicing costs.


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Repair Vs. Replacement

Owning Costs

Salvage Value

Operating Costs

Productivity

Downtime

Total Cost


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When to Replace?

There comes a time when it is best toreplace a machine rather than keeptrying to repair it.

This decision should be made oneconomics.

Heres how to do it.


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Owning Costs

Owning Costs

include:

Purchase & Financing

Insurance & Tax

Decrease over time

The more hours amachine is used, themore hours its cost is

spread over.

Machine Hours


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Operating Costs

Operating Costs

include:

Fuel, Oil & Filters

Service, Maint. & Repair

Rebuilds & Accessories

Increase over time

The older a machine isthe higher its operating

cost

Machine Hours


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Productivity Costs Productivity Costs

The cost to produce agiven amount of workwill decrease as a

machine gets older Also, when compared

to a new machine, theold machine loses 1%or so each year

Machine Hours


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Downtime Costs

Downtime Costs

As a machine gets olderit will tend to have moredowntime due to repairs

And, as you know thereis a cost associated withdowntime

lost compaction

replacement machine

hinder or shut down job

Machine Hours


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Add up All Costs?

When you add up allthe costs of owning amachine, youll see

that over time itbecomes more andmore expensive

Wait like all rules,

there are exceptions

Machine Hours

ReplacementPeriod

New

Old


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Exceptions to the Rule

If you do repairs on-site or

If downtime is not a major issue or

if you just LIKE doing the repair and dontconsider the cost or

if the workload is so light that an oldmachine is sufficient

Then it may make sense to keep it


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Track Machine Utilization

I suggest that the utilizationrates for all machines betracked. Machines with lowrates should be closelyevaluated in terms of whether

a rental (or alternative)machine would be moreefficient or economical.


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Working Hour Summary

Landfill Activity

30

47

58

70

77

78

82

85

108

137

170

190

0 20 40 60 80 100 120 140 160 180 200

Tarping Unit

Fuel/Lube Truck

New Loader 924G

Water Truck

Excavator

Crawler Tractor D5C

Loader/Skid Steer 226

Small Excavator

Articulated Dump Truck

Wheel Loader

Compactor

D8R Cateerpillar

VehicleDescription

hours per month

Hours/month


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% Utilization Summary

Equipment Yearly Usage

18%43%

26%

54%

24%

27%

60%

25%

15%

34%

22%

9%

0% 10% 20% 30% 40% 50% 60% 70%

Loader 924G

Wheel Loader 980

Skid Steer 226

826 Compactor

Excavator 330C

Excavator 307

D8 Dozer

D5 Dozer

Fuel-Lube Truck

Articulated Dump Truck

Water Truck

Tarping Unit

Total Hrs. Per Yr./Open Hours


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Landfill Shop How Big?

As you might expect,landfill shop sizevaries in relation to

tonnage. Bigger landfills

typically have biggershops.

Shop Size vs. Tons per Day

0

5,000

10,000

15,000

20,000

25,000

0 500 1000 1500 2000 2500 3000 3500 4000

Tons per Day

Shop

Size

(square

fee

t)


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Landfill Shops vs. Machines

The number ofmachines also

has an impact onthe size of thelandfill shop.

On average,shop size seemsto run at ~460sfper machine.

Total No. of Machines Vs. Shop Size

0

5,000

10,000

15,000

20,000

25,000

0 5 10 15 20 25 30

Total No. of Machines

Shop

Size(squarefeet)


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Service/Repair Staffing

If we looked atservice/repair

workers, wed find~ 1 worker forevery 6 machines.

No. of Machines per Worker vs. TPD

0

2

4

6

8

10

12

14

16

0 1000 2000 3000 4000

Tons per day

No.ofMachines

05 Equipment Maintenance

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