ETF Haulage Trucks Agadir, May, 2013 Advanced Maintenance Systems

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Transcript of ETF Haulage Trucks Agadir, May, 2013 Advanced Maintenance Systems

  • Slide 1
  • ETF Haulage Trucks Agadir, May, 2013 Advanced Maintenance Systems
  • Slide 2
  • Content Modular Technical Design F-1 Pit-Stop System Fast Components Exchange TRMS: Truck Repair Monitoring System Maintenance & Repair Sequence Electronic Data Collection Flowcharts: F-1 Pit-Stop System Component repairs Part repairs Unique Test Facility For Engines and Axles Workshop & Team What Automatic Data Processing Enables Global Technical Organization Summary
  • Slide 3
  • Major Components Conventional trucks: Each size has different major components (Engine, frame, axles, drive line, tires) All ETF trucks have the same major components (Power-Modules, Tires & Axle-Groups)
  • Slide 4
  • 95 % Technical Availability by Fast Component Exchange System! Maintenance & Repair is done in the Workshop without the Vehicle! Components are Exchanged and Vehicle Returns to Production within: 15 minutes for Wheels, Power-Modules & Cabins 25 minutes for Axle-Groups
  • Slide 5
  • Modular Design Modular Technical Design for all Truck Types Enables Fast Repairs Enables Container Transport Considerable Reduction of Spare Parts Stock More Economical Manufacturing Trucks can Continue Production even with a Technical Fault that could shut down a conventional truck for days! Engine shuts down: Truck still mobile! Flat tyre: Truck still mobile! Wheel-motor defect: Truck still mobile! Hydraulic defect: Truck still mobile! Trucks always able to return to the Workshop No blocking of Haul Roads, Loaders and Hoppers No Tow Truck Required
  • Slide 6
  • Modular Design Advantages Maintenance & Repair is completed in the workshop without the truck! Components are exchanged and truck returns to production within: 15 minutes for Wheels, Power-Modules & Cabins 25 minutes for Axle-Groups Considerable Reduction of Parts Stock for all Truck Types Identical Power-Modules Identical Axle-Groups
  • Slide 7
  • Major Components in Containers
  • Slide 8
  • Power-Module Changed in 15 minutes Unique Removable Power-Module designed for easy Exchange & Maintenance
  • Slide 9
  • Axle-Group Changed in 25 minutes
  • Slide 10
  • Fast Tire Changes in 15 minutes!
  • Slide 11
  • TRMS : Truck Repair Monitoring System All Employees Registrations via Fingerprint recognition All Individual Components/ Parts have RFID Tags / Barcodes For Electronic Data Processing Avoiding Human Error Integrated Preventive Maintenance Avoiding Unscheduled Repairs Technical Status of Components Permanently Monitored Global Trends in Operational Performance scrutinized by ETF Immediate Remedial Action taken if necessary Automatic Parts Ordering from European Stockholding Assures Delivery with Shortest Lead-times Automatic Warrantee Processing
  • Slide 12
  • In Case of Vehicle Fault: Message displayed to Operator & Workshop (in the local language!) When Convenient to the Operation (not when Hauling on grade, loading or unloading) truck returns to the workshop Informed Technicians are Ready with New Exchange Component Truck arrives at Workshop; Component is Exchanged Truck Back in full Production between 15 and 25 minutes later! Truck Back in full Production between 15 and 25 minutes later! Minimal Loss of Revenue! F-1 Pit-Stop System:
  • Slide 13
  • Automatic Tag Reading upon Entrance & Exit Workshop (Chassis, Power-Modules, Axle-Groups, Cabin, Dump-body & Tyres) Automatic Operating Hours Registration of Truck, Components & Tyres Reduces Maintenance and Inventory Costs Reduces Human Error
  • Slide 14
  • Maintenance & Repair Sequence: Stage 1: F-1 Pit-Stop System - Major Components Exchange - Enables 95% Technical Availability during Full Life Cycle Stage 2: Component Repair - Assures Components Availability Stage 3: Parts Repair - Reduces Costs
  • Slide 15
  • Stage 1: F-1 pit stop Flowchart: OPERATOR & WORKSHOP Alerted for Technical Fault by Truck Computer Technicians log in by Fingerprint and Prepare Exchange Component Manager assigns Technicians Truck, Components & Tyres Reading Truck Downtime Registration Truck Operating Hours Registration Job Data on Workshop Monitor Truck, Components & Tyres Reading Truck Downtime registration Truck Operating Hours registration Component Operating Hours registration Tyres Operating hours registration Component Repair Job assignment Job-Time registration Truck goes to workshop Automatic RFID Reading Upon Truck arrival in Workshop Prepared Component Exchanged Automatic RFID Reading Upon Truck exit from Workshop Truck returns to Operation Technicians log out
  • Slide 16
  • Stage 2: Component Repair Flowchart: Component Technical History Update Component Tested Component Barcode/RFID Scan Component returned to Stock Technician logs out COMPONENT WITH FAULT With Automatically generated Job number Technician assigned to Job Component Barcode/RFID Scan Fault Diagnosis on Test Equipment Defective Part Scanned & Exchanged Job Time registration Technician logs in by Fingerprint Component Registration Part Operating Hours registration New Part sourced from Stock Part Repair Job assigned To find Defective Part
  • Slide 17
  • Stage 3: Part Repair Flowchart: Part is Tested PART WITH FAULT with Automatically generated Job number Technician logs inTechnician assigned to Job Part Registration Part Barcode/RFID Scan FAULT DIAGNOSIS ON TEST EQUIPMENT Part Technical History update Automatic Warrantee Claim Automatic Stock Update Automatic Part Ordering Registration Job Time Technician Time registration Part Barcode/RFID scan Part returned to Stock Technician logs out Part Operating Hours registration New Sub-Part sourced from Stock Defective Part Repaired A. REPAIRABLE Automatic Warrantee Claim Automatic Stock Update Automatic Part Ordering Registration Job Time Technician Time registration Technician logging out Part Operating Hours registration Part Technical History update Part Scrapped B. NON-REPAIRABLE
  • Slide 18
  • Unique Test facility for Power-Modules and Axle-Groups After the repair is completed all components are fully tested Repair errors corrected without additional truck downtime
  • Slide 19
  • Workshop design Workshop roof is equipped with 5,100 m 2 of Solar Panels generating between 0,7 & 1,9 MW of renewable energy. Power, lighting, heating and ventilation costs are kept to a minimum by utilizing this renewable energy.
  • Slide 20
  • Workshop & Team Dedicated Workshop, Repairs carried out inside! G uarantees best possible quality and shortest repair times Dedicated Team trained for the Trucks and the System Right mind-set Qualified for Truck Repair Monitoring System (TRMS) Special Tooling and Major Components always on-site: Power-Modules, Axle-Groups, Tires, Cabins, Body, Tipper cylinders, Steering cylinders, Hydraulic pumps & motors etc. On-site Activities: All Repairs and Overhauls (mechanical, hydraulic & electronic) enabled by unique test facility for Power-Modules and Axle-Groups Fabrication of Hydraulic hoses Tire repairs Body repairs
  • Slide 21
  • Automatic Data Processing Enables: The Client:- Truck Operational Data Registration - Truck Downtime Registration ETF Project:- Component & Parts Operating Hours Registration - 24/7 Updated Stock-list & Automatic Ordering - Component & Parts Technical History Registration - Technicians Working Hours Registration ETF Germany: - Global Monitoring of all Components Exchanges - Trends in Operational Behavior of Components RESULTING IN: - Best Possible Truck Performance - 95% Technical Availability during Full Life Cycle - Sustainable Quality Improvement
  • Slide 22
  • ETF Technical Organization German Headquarter is connected on-line with all Projects World-wide (24/7/365) Global monitoring of all components exchanges and repairs Automatically generating parts requisitions from ETF central stockholding Trends in operational behavior of components are monitored and immediate action is taken if necessary
  • Slide 23
  • Most Advanced Maintenance & Repair System in the Industry In Speed In Quality In Costs 24/7/365 Stock Updating with Automatic Parts Ordering Reducing Human Error All Parts in Stock in Europe Shortest Possible Lead Times PROVIDES: Superior Truck Performance Superior Truck Performance 95% Technical Availability during Full Life Cycle 95% Technical Availability during Full Life Cycle Sustainable Quality Improvement Automatic Warrantee Processing Automatic Warrantee Processing Lowest Costs per Ton Lowest Costs per Ton ` MODULAR TECHNICAL DESIGN & ADVANCED IT Results in:
  • Slide 24
  • ETF: Mining Solutions for the 21 st century Mining Solutions for the 21 st century Thank you for your attention! www.etftrucks.eu