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Hemm Additional

The one day heavy equipment seminar covered effective equipment maintenance management and maximizing productivity. It included discussions on the 3 pillars of equipment management, cost per ton concept, profit and operating costs, equipment life cycles, availability and utilization metrics, and the 7 elements of effective equipment management including preventative maintenance, inspections, repair management, and use of a maintenance control system. The seminar provided information to help customers effectively manage their heavy equipment for lower costs and higher productivity.

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Fiza Ilmi
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© © All Rights Reserved
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54 views95 pages

Hemm Additional

The one day heavy equipment seminar covered effective equipment maintenance management and maximizing productivity. It included discussions on the 3 pillars of equipment management, cost per ton concept, profit and operating costs, equipment life cycles, availability and utilization metrics, and the 7 elements of effective equipment management including preventative maintenance, inspections, repair management, and use of a maintenance control system. The seminar provided information to help customers effectively manage their heavy equipment for lower costs and higher productivity.

Uploaded by

Fiza Ilmi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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CUSTOMER GATHERING

One Day Heavy Equipment Seminar


Effective Equipment
q p Maintenance Management,
g ,
Maximize Productivity
Dipresentasikan Pleh :

Rudityo
y Priyo
y Huntoro (Rudy)
( y)

PT Trakindo Utama
Training & Development Center Dept
(021) 8233361

Klaten – Jateng
Hobby : Hidup Sederhana

rhuntoro@trakindo.co.id
rudityo_ph@yahoo.com

HP : 0811972504
FISHBONE CONCEPT
MAINTENANCE MANAGEMENT
SECTION
3 PILLAR OF EQUIPMENT MANAGEMENT
Cost Per Ton CONCEPT
Profit - Iceberg law

Intial Price
(Unit Price)

Operating Cost
Non Productive Cost
Used Equipment
Selling Price
Availibility Unit
Productivity
Equipment Life Cycle

Note : Sample
p Only
y
Truck PCR Life Cycle

Note : Sample
p Only
y
MTBS – Mean Time Beetwen Stopages

Note : Sample
p Only
y
MTTR – Mean Time To Repair

Note : Sample
p Only
y
Availability Index

( Your KPI ..? )

Note : Sample
p Only
y
Increase - MTBS
Decrease - MTTR
Customer Need / Dealer Capabilities
Time Definition
Availability
y & Utilization
(An Example)
Job Efficiency Factors Machine Availability Loss Utilization Loss Off Time Loss
• Mismatch • Unscheduled Downtime • Ready, but unmanned • Holidays
• Bunching (90% On-Shift Availability) • Shift Change • Weather
• Operator
O Effi
Efficiency
i • Lunch
L h & Meetings
M i (4 1% Off Time)
(4.1% Ti )
(85% Job Efficiency) • Sched. Downtime & PM’s
(87.5% Utilization)

PRODUCTIVE TIME 735 1050 360


6615 HRS HRS HRS HRS

Machine Operating Hours


(6615 HRS) 10% 12.5% 4.1%
of of of
Machine Scheduled Hours 7350 8400 8760
(7350 HRS)

Mine Scheduled Hours


(8400 HRS)

Total Annual Hours


(8760 HRS)
Time Definition
Term Definition
5 Stage Of Maintenance Management
Maintenance
Impact On Profitability
7 Element of Equipment Management
Preventive Maintenance
S O S Program
S O S Program

• Windows based
software
• Track S•O•S
samples for all
equipment
• Lab interaction
• Detailed reports
• Graphing
• Fleet monitoring
S O S Program

• We know Cat equipment better than anyone


• We have vested interest in y
your success
• We get information to you fast
• We help find right solutions
• We keep records on your machine
Inspection
Inspection
Gambar apa ini…?
Training
Schedulling
Repair Management
Repair Cost Comparison
Final Drive Repair Cost Comparison
Record Keeping
Maintenance Control System

• Inspections
• Scheduling
• Record keeping
Maintenance Control System

• Track all elements of your maintenance program


• Be alerted when service, inspections, and repairs are
needed
d d
• Predict labor and parts needs for a repair
• See when work was completed
• Keep detailed cost records by machine and component
Maintenance Control System

Asset Watch Maintenance Watch Health Watch


• Machine Location • Planned Maintenance (PM) • Event and Diagnostic Codes
• Machine Location Mapping History • Event and Diagnostic Code
• Machine Location History • PM Notes Troubleshooting Procedures
• Non-reporting
N ti M
Machine
hi • Next PM Due • Event and Diagnostic Code
Identification –(date or hour based) Alerts
• Machine Hour Reading • PM Alerts • Event and Diagnostic Code
• Machine Hour History • PM Checklist History
• PM PParts Li
List • Fuel Level
• Customized PM Checklist • Fuel Used
• PM and Repair Planner • Fuel Level Alert
• On-line Parts Ordering • Fuel Used History & Graphic
Display
• Manage Major Repairs
• Fuel Level History
• Backlog Record & Strategy
• Refueling History
• Repair History
• PM or Repair Request for Quote
Maintenance Planner Utility

• Daily Jobs
• Planning
l
• Strategy
Cat Parts
Level I , Parts - Engines
Level I , Parts – Drive Train
Level II , Parts – Engines
Level II , Parts – Draive Train
Level III , Parts – Engines
Level III , Parts – Drive Train
Life Cycles of Parts/ Component
Life Cycles of Parts/ Component
Repair Cost Vs ComponentLife

Broken

Hour
Cost

nce Cost /H
Repair C

Limit Of Max Repair

Still Good

Comp Life Time


Comp. Maintenan

Comp. Life Time


Revolution – Load Sensitive Item

Revolution Sensitivity Load Sensitivity

Load 50 %

Load 100 %
ar
Wea

Wear
X X X

Time / Operation Hours Time / Operation Hours


Operating Cost Composition

SAMPLE WHEEL LOADER OPERATING COSTS

Repairs
27%

Operator
Fuel 28%
24%

Oil/Filters
Tires Wear 3%
12% Items
6%
Caterpillar Fluids Filter

• Fiberglass spiral roving, acrylic beads


• Non‐metallic
Non metallic core
• Thick, one‐piece base plate
• One‐piece, molded urethane
end cap
• Heavy gauge can
High Efficiency Fuel Filter

• 2 Micron
Filtration
• High Efficiency
Media
• Check Valve
Cat Air Filters

• Longer service
life
• More seal
contact
• Superior
capacity
• Radial seal
d i
design
Cat Turbin Pre-Cleaner

• Expel all types of heavier‐than‐air debris


• Lower cost per operating hour
• Greatly extend air filter life and reduces maintenance downtime
• Lower overall engine
maintenance costs
• Improve fuel
f l economy
and engine performance
• Work in all weather
conditions
d
• Reduce downtime
Cat Diesel Engine Oil

• Optimizes life and performance


• Exceeds API CG4 requirements
• Low emissions designs
• Soot stays suspended
• Preferred factory fill
Cat Transmission/ Drive Train Oil

• Optimizes life and gear performance


• Exceeds
E d iindustry
d t TO‐4
TO 4 standards
t d d
• Eliminates transmission slippage
• Increases
I clutch
l h disc
di life
lif up to 45%
• Controls brake chatter
• Increases machine break‐out force
• Provides greater machine rim pull
Cat Extended Life Coolant

• Preferred factory fill


• Twice coolant life of
predecessor
• Extender needed only once
• Use in most OEM engines
g
• Environmentally friendly
• Reduced cost
Repair Management
Daily Inspection
Planned Indicator
Planned Indicator
Gambar Apa dibawah ini..?
Technical Analysis
Overhaul Management Guide
Problem Indicators
Repair Management
Customer Have Option
Consideration
Repair Option
Selecting Engine Repair Option
Selecting Drive Train Repair Option
Using “Correct “ Parts
Contamination Control
Contamination Control
Contamination Control
What is Contamination..?
Drive Train Effects of Contamination
Contamination Prevention
Contamination Prevention
Oil Storage & Transfer
Parts Handling & Oil Storage
Particle Count
Maintenance Made Easy
OPERATOR
SECTION
OPERATOR
OPERATOR
OPERATOR
OPERATOR
OPERATOR
OPERATOR
OPERATOR

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