Caterpillar & Dealers (Gmmco, TIPL)
Supporting CIL’s 1 Billion Ton+ roadmap
Pinaki Chatterjee
20 Jan 2015
OUR COMPANY - CATERPILLAR
• Estd. in 1925 as Caterpillar Tractor Co.
• HQ - Peoria, Illinois State, USA
• Manufacturing of earthmoving & mining
equipment, diesel & gas engines and also
involved in the financial products business
• 110,000+ employees WW
• 88+ years of dealer network history
– 178 dealerships WW, 160,000+ dealer employees
– $ 21.8 Bill dealer net worth
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/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
OUR INDIA DEALERS – Gmmco, TIPL
• Gmmco
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Established in 1967, HQ- Chennai
Turnover ~ US $ 400 Mill
28+ years of association with Caterpillar as dealer
Manages 8200 machines & 8300 engines in its territory
• TIPL, a subsidiary of TIL
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TIL established in 1945, TIPL in Apr 2010 to exclusively handle Cat portfolio
HQ - Kolkata
TIPL turnover ~ US $ 250 Mill.
70+ years with Caterpillar as dealer
Manages 8000 machines & 7200 engines
• www.caterpillar.com, www.cat.com, www.gmmco.in, www.tiplindia.in
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INDUSTRIES WE SERVE, OTHER SERVICE AREAS
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INDUSTRIES
– Mining
– Construction
– Electric Power Generation
– Locomotive & Railway
– Oil & Gas
– Paving
– Quarry, Aggregates and Cement
– Marine
– Material Handling
– Pipeline
– Forestry
– Demolition and Scrap Recycling
– Waste
– Agriculture
– Landscaping
– Governmental & Defence
– OEM Solutions
– Power Plants
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
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SERVICE AREAS
– Technology & Solutions
– Rental
– Maintenance and Repair
– Financing
– Insurance
– Remanufacturing
BROADEST PRODUCT LINE IN THE MINING INDUSTRY
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MACHINE RANGES - SURFACE
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MINING
TRUCKS /
DUMPERS
40 / 50 / 60 / 70 / 100 / 150 / 190 / 240/ 320 / 350 / 400 (tons)
ELECTRIC
ROPE
SHOVELS
50 ton : 19-38 cu.m. / 70 ton : 20 – 55 cu.m. / 90-120 ton : 27 –
62 cu.m.
HYDRAULIC
SHOVELS
105 ton (6 cu.m.) / 180 ton (10 cu.m.) / 300 ton (17 cu.m.) / 407
ton (22 cu.m.) / 535 ton (28 cu.m.) / 570 ton (34 cu.m.)
WHEEL
LOADERS
290 hp (4-4.5 cu.m.) / 350 hp (4.8-5.4 cu.m.) / 540 hp (5.4-5.8
cu.m.) / 410 hp (6.2 cu.m.) / 625 hp (7.5 cu.m.) / 815 hp (10
cu.m.) / 1025 hp (13 cu.m.) / 1460 hp (17 cu.m.)
DRAGLINES
76 – 96 m (20-32 cu.m.) / 100 m (41-61 cu.m.) / 110 – 132.5 m
(76-116 cu.m.)
ROTARY
BLAST HOLE
DRILLS
(270 mm, 55.5 m max, 48 cum/min) / (311 mm, 74.4 m max,
67.9 cum/min) / (381 mm, 84.7 m max, 102 cum/min) / (406
mm, 42.7 m max, 107.6 cum/min) / (444 mm, 39.6 m max, 108
cum./min)
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
MACHINE RANGES - SURFACE
TRACK
DOZERS
300 hp, 410 hp, 600 hp, 850 hp
WHEEL
DOZERS
355 hp, 500 hp, 630 hp, 815 hp
MOTOR
GRADERS
14 ft, 16 ft, 24 ft blade
HIGHWALL
MINERS
305 m (28-38” dia drum, 2.95-3.5 m drum width, 8-10
deg pit floor, 8 deg max. seam gradient)
BELT
CONVEYORS
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1800-2200 tph / 9000 tph
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MACHINE RANGES – UG - CM
CONTINUOUS
MINERS
FEEDER
BREAKERS
FACE
HAULERS,
CONTINUOUS
HAULAGE
ROOF
BOLTERS
(under devl.)
UTILITY
VEHICLES
(SCOOPS,
LHD)
BELTS
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.81m – 4.7 m seam heights,
860, 1150, 1390 tph
Battery (10, 19 tons), Diesel (22 tons)
Cont. Haulage – 20, 30 tph
Upto 2.3 m drill boom feed,
Scoops carrying capacity – 7 to 16 tons
LHD – 2.7 cu.m. (8,10 tonnes payload), 3.5 cu.m. (10
tonnes), 4.5 cu.m. (15 tonnes),
1800-2200 tph / 9000 tph
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
MACHINE RANGES – UG - PSLW
SHEARERS
PLOWS
1.8 – 7 m seam heights, upto 45m/min cutting speed
(Max. 5000 tph), Single, Double & Three drum shearers
0.8 – 2.3 m, upto 3.6 m/s travel speeds, Max. 3500 tph
ROOF
SUPPORTS
.5 m – 6.1 m, Upto 111 tonne/sqm shield density
ROOF
SUPPORT
CARRIERS
40 – 60 tons payload capacity
ARMOURED
FACE
CONVEYOR
SYSTEMS
BEAM STAGE
LOADERS
CST DRIVE
SYSTEMS
Upto 500 m length, 660 - 6200 tph
Line pan (2000-7000 tph), Crusher (1500-8000 tph),
300,000 Nm – 1150,000 Nm Torque
AUTOMATION
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MANUFACTURING FACILITIES WORLDWIDE
Caterpillar Global Mining
Headquarters
WISCONSIN, US
Truck Bodies
Draglines &
Electric Rope Shovels
Articulated
Trucks
WISCONSIN, USA
UNITED KINGDOM
Excavators, Wheel Loaders
& Wheel Dozers
RUSSIA
Mining Trucks
RUSSIA
Longwall
CZECH REPUBLIC
ILLINOIS, USA
Track-Type Tractors,
Mining Trucks, Motor Graders
& Scrapers
Longwall
Room & Pillar, Longwall,
Highwall, Conveyors EASTERN
ILLINOIS, USA
CHINA
USA
Hard Rock
Underground
Drills
TEXAS, USA
Mining Trucks
MEXICO
Truck Bodies
Motor Graders
ARKANSAS, USA
Longwall,
Hard Rock Underground,
& Hydraulic Shovels
GERMANY
MEXICO
Mining Trucks
THAILAND
INDIA
Truck Bodies
INDONESIA
Hard Rock
Underground
TASMANIA
Hard Rock
Underground
BRAZIL
Map is for illustrative purposes and is not intended to reflect every facility
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CAPACITIES
USA
GERMANY
AUSTRALIA
INDIA
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Decatur
150+ ton Trucks
> 1500 / yr
- Do -
24 ft Motor Graders
> 130 / yr
South Milwaukee
Electric
Draglines
Aurora
Wheel Loaders, Wheel Dozers
WL : > 800 / yr ; WD : 200 / yr
Texas
RBH Drills
> 70 / yr
East Peoria
Track Dozers
> 1800 / yr
Arkansas
14, 16 ft Motor Graders
> 350 / yr
Pennsylvania
Highwall Miner
~ 5 / yr
- Do -
Continuous Miners,
Breaker, Roof Bolter
Virginia
Belt Conveyors
Lunen
Longwall
Custom
Dortmund
Hydraulic Mining Shovels
> 125 / yr
Beresfield
Diesel Coal
Vehicle
Thiruvallur
60, 100 ton Trucks
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Rope
Shovels,
Hauler,
Feeder
ERS : > 20 / yr ; DGL : Custom
CM : > 20 / yr
Utility
> 1000 / yr
TECHNOLOGY
• Product Link
– Remote monitoring / Asset Tracking through
Cellular communication
– Secure web based solution
– Insight into machine operation, health,
productivity
– Customisable, maintenance alerts can be set
– Few features visible are machine working
hours, fuel consumption, physical location,
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AFTER SALES SUPPORT
• Service Support
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Troubleshooting & Product Problem Resolution
Condition Monitoring Services
Technical Audit Services
Custom Hydraulic Services
Custom Track Services
Component/ Sub Assembly exchange programs
– Guaranteed availability contracts
– Parts cap / cost cap guarantee contracts
• > 130 machines
– MARCs (Full Maintenance & Repair)
• 255+ machines, including 240 ton trucks, 42 cu.m.
ERS, 34 cu.m. HMS
– Customer Infrastructure consultation
• Gevra workshop for 240 ton trucks
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AFTER SALES SUPPORT
• Service Support
– Sub assembly
repairs
repairs,
Major
component
• 5 workshops, Nagpur, Chennai, Asansol, Delhi,
Udaipur. Some are 5 & 4 Cat certified
• Machine Power train rebuild & test bench facility
– Machine rebuilds
• Nagpur & Asansol Machine Rebuild Centre
– SOS (Scheduled Oil Sampling)
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AFTER SALES SUPPORT
• Parts Support
– Infrastructure
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80 Warehouses, 5 Main depots, > 86,000 lie items
Inventory > INR 375 cr
Contamination Control certified stores
Online connectivity between various dealer
branches as well as various Cat parts distribution
facilities
• Online transaction processing
• Dealer Stock service level > 92%
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Parts cap / cost cap guarantee contracts
Component / Sub Assembly exchanges
MARCs (Full Maintenance & Repair)
Spares Depot Agreements / Rate Contracts
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
AFTER SALES SUPPORT
• Service Training - Customer
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Classroom
Training lab
Field
NPI / NMI
• Operator Training
– Classroom
– Simulator
– In-the-iron (machine)
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AFTER SALES SUPPORT
• Skill building
– Mining machine operator bank
– Mechanical & electrical technician training at school levels
– A “desired place to work” environment to attract and retain talent
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OUR THOUGHTS …
• INCREASING PRODUCTION
– Increasing machine utilisation
• Product Link technology deployment
• Analysis of operating hours leakages
– Usage of Electrically powered Hydraulic Mining Shovels
• Faster equipment
• Using existing electrical infrastructure
• Controlling input fuel costs (diesel vs electricity)
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OUR THOUGHTS …
• INCREASING PRODUCTION
– Enhance usage of Highwall Miners
– Adopt Plow technology for UG coal in thin seams below 1.5m
– Use of appropriate mining equipment having long term
replacement cycles
• Long term outsourcing contracts
– Consignment spares stocks in each subsidiary HQ
– Combining OC mines & even in UG operations to drive
economies of scale
• Dragline operations
– Locked coal pillar extraction without surface rights
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OUR THOUGHTS …
• EQUIPMENT PROCUREMENT
– Reduce tender periods
• Bonafide and proven suppliers
– DPRs
• Outsourcing tenders to have minimum adherence to DPR
recommended equipment packages
• DPRs need to be revisited for incorporation of latest technologies,
newer equipment classes / upgrades
– Review recommended during equipment replacements in existing
projects
– Safety, Enabling better compliance with environment norms
– Adoption of international standards, reduce in-country testing &
certification for UG equipment
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OUR THOUGHTS …
• EQUIPMENT PROCUREMENT
– Equipment survey off norms to be increased
• Helps planning during equipment replacements
• Allows for economic machine rebuild lives in line with global
standards
• Lowers owning cost exposure
– Alliances by projects
• Package purchases, reduction in no. of suppliers, tenders and
purchase time
– Incorporation
conditions of
of
clauses
to
reward
suppliers
exceeding
• Guaranteed availability, Higher utilisation hours, longer survey off
life, wider established product support infrastructure, globally
accepted technological features, etc
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OUR THOUGHTS …
• OTHERS
– Use of OB (crushed) in road building, construction activities
• Revenue generation, saving dumping space
– Feasibility of long distance belt conveyors from mine to end user
or coal loading sidings
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®
© 2013 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, their respective logos,
“Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product
identity used herein, are trademarks of Caterpillar and may not be used without permission.
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PRODUCTION/ PRODUCTIVITY ENHANCING FEATURES
• Various bucket and boom options on draglines
• Tri-Power structure on Hydraulic Mining Face Shovels
– Faster cycle times, more breakout force
• Custom bodies on trucks to maximise payload
• Autonomous operation feature for dozers for safe use on berm edges
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Safety … Our vision - Safely Home. Everyone. Everyday
– Machine design safety
– Personal protection
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