Komatsu 7th GTI
Reduce Down Time on 930E fleet
in AJL coal mine
Li Guohui
Komatsu (China) Mining Ltd.
Product Spport Section
Service Department
2012-3-2
1
Komatsu 7th GTI
Agenda
1、 Background of AJL Coal Mine
2、Introduction of Komatsu (China) Mining Ltd
3、 Availability review of 32 x930E fleet
4、 Machine down time analysis and action（ GENBA）
5、 Future action plan
2
Komatsu 7th GTI
1、Background of AJL Coal Mine
China Coal Ping
Shuo Coal Co.Ltd.
ATB Coal Mine
AJL Coal Mine
East Coal Mine
Komatsu
Mining Machine Population
125
105
85
65
45
25
5
-15
TTL:121 units
32
13
1992
1998
1999
2001
2002
2005
2006
2007
19
2008
2009
2011
TTL
D475A-5EO
2
6
3
11
930E-4
13
19
WD600-6
WD600-3
D375A-5
WD600-1
4
730E-7
29
D375A-3
2
2
1
2
4
4
2
4
2
8
1
4
4
2
31
10
GD825A-2
D375A-2
32
2
10
7
2
17
2
China coal is one of biggest
customer for KCML.
KCMLhave been committed to
the customer first.Support the
customer and keep Komatsu
machine high availability.
So how to reduce machine
downtime is very improtant
and urgent!
3
Komatsu 7th GTI
2、 Introduction of Komatsu (China) Mining Ltd. /(KCML)
Huolinhe SS
M/P:58
Established: Sept.2010
Total SS, 8 and Staff, 93
Average experiece:1.98 yrs.
Machine population:595 units
- 332 Dump trucks
- 263 Construction machines
ShengLi SS
Datang SS
M/P:51
Baotou SS
M/P:12
Zhungeer SS
M/P:135
Parts
warehouse
Beijing HQ
Pingshuo SS
M/P:262
KCRC 44P
Rebuild Center
Dexing SS
M/P:61
Chengmshan SS
M/P:12
4
Komatsu 7th GTI
2-1、Organization Chart of
KCML Product Support Div.
Mr.Zhangquanwang Vice president
KCRC
Service Dep.(103P)
Part Dep.
Lijun GM
Mick_Matsumoto GM
Xinghao GM
Mining Support
Center(93P）
Quality&Rely Dep
Yokota Manager
Pingshuo
Zhungeer
SS Mgr
SS Mgr
Dexing
SS Mgr
Chengmenshan
SS Mgr
Shengli
SS Mgr
Huolinhe
SS Mgr
Baotou
SS Mgr
Product Support Div.(144P)
Management Section
Operation&Tecchnical
Liguohui Manager
TBA
Huanghuifen Manager
Kudou
Gaoyang
Ralph
TBA
Customer support and SS support
Quality control and operation
Service system operation
SS
Manager
Baiyinhua
Planner
Mechanic
Mechanic
Parts
Supervisor
Mechanic
Mechanic
Mechanic
5
Komatsu 7th GTI
3、Availability of 32 x930E in AJL for the period of Jan. 2011 to Dec. 2011
100.0
400
90.0
350
80.0
300
250
60.0
50.0
200
40.0
150
30.0
MTTR /MTBF
AVAILABILITY
70.0
100
20.0
50
10.0
0.0
Physical availability
Utilization
MTTR
MTBF
JAN
84.8
FEB
86.6
MAR
86.8
32 units 930E’s Contract
Availability Review (the last
unit delivered in Dec.2009 )
APR
84.7
MAY
91.3
JUN
93.6
JUL
93.0
AUG
86.3
88.9
18.4
144.9
SEP
90.2
90.4
21.3
125.0
OCT
87.5
86.4
17.7
148.6
Nov
87.1
75.7
18.7
143.1
DEC
84.5
90.1
23.7
129.2
Ave.
87.9
82.3
18.7
119.1
0
Year Warranty condtion Fleet avaibility target Unit avaibility target
1
2
3
Standard warranty
Extended warranty
KCML(Target)
92%
90%
88%
90%
88%
85%
6
Komatsu 7th GTI
4、 Machine Down Time Analysis Through KCML Monthly Report
Down time hour status for AJL’s 32 units of 930E (Jan.2011~Dec.2011)
(Excluding-tyre and Engine D-check)
3500
Down time H
3000
2500
2000
1500
1000
500
0
Accident
RP2 Contactor
Automatic lubrication
Suspension
Chassis
Hydraulic
Dump body
Main alternator
Engine
Jan
Feb
Mar
Apr
May
50
Jun
Jul
Aug
Sep
Oct
Nov
43
75
Engine is the biggest
factor of103
downtime
180
78
87
183
232
348
1740
72
882
1920
503
1407
222
497
332
388
440
Dec
549
60
319
734
Accident
RP2 Contactor
Automatic lubrication
Suspension
Hydraulic
Dump body
Main alternator
Engine
334
86
298
282
68
502
350
157
689
300
1433
Chassis
7
Komatsu 7th GTI
4-1、 What is the problem on the engine and Why?
Identify potential root causes for engine down time using
fishbone diagram （draft)- hypothesis
Quality
Repair
Tool & facility
Material
Lack of
inspection tools
Troubleshooting
Manpower
Assemble
Lack of tester
Management
FC issue
Design
Experience
Coolant
Oil
No place
Cold start
Not On time
Sudden stop
Environment
Operator
Engine
breakdown
Local parts
Accident
Lead time
Parts error
Speed control
Air
Maintenance
Lack of
facility
No standby and
stock
Parts
8
Komatsu 7th GTI
4-2、Engine Down Time Analysis(Jan.2011-Jul.2011)
Engine downtime status (Jan.2011-Jul.2011)
5000
4000
3000
1.20
3976
88%
96%
92%
98%
99%
1.00
100%
57%
2166
0.80
0.60
2000
0.40
1000
288
256
131
1、No standby
engine
0.20
90
41
0
2、Cylinder head
crack
0.00
No
Cylinder Coolant
standby head
leaked
engine damaged
Oil
leaked
Down Time H
Turbo. Intake Tension
Fault manifold pulley
broken bearing
failed
Accumulate%
Stock necessary
engine at jobsite
since Apr.2011
Cleaned cooling
system and replace
coolant
Return engine to
jobsite after
overhaul
Provided 128 pcs
head cylinder to
customer
Standby engine situation as of Jan.2012
Customer
No.of Dump
Truck
PingShuo (ATB/AJL/East
mine)
90
Customer
New Rebuilt Under OV
2
16
On Ship
New
2
2
CEBJ / Cummins
Rebuilt Under OV
-
On Ship
3
Total
25
9
Komatsu 7th GTI
4-3、 Engine Down Time Analysis(Aug.2011-Dec.2011)
Engine downtime status (Aug.2011-Dec.2011)
2400
2036
1.20
8 units engine need to
remove and reinstall
2000
100%
93%
79%
1600
44%
1200
1.00
0.80
1024
0.60
800
0.40
400
103
72
Maintanence
Engine
troubleshooting
0
0.20
0.00
Remove and Re
intall engine
Cylinder head
Down Time H
Accumulate%
Machine operate Hours & engine O/V status (as of Jan.2012)
1、The engines have to
overhaul based on
machine operate hours
（20000 Hours）.
2、What are the root causes
for the long time needed
for the engine to be
removed and re- installed
with standby engine?
 Unschedule overhaul
 Schedule overhaul
25000
20000
SMR
15000
10000
5000
0
10
Komatsu 7th GTI
4-4、Engine Replacement Process (GENBA) /Root Cause Analysis And Action
Machine
Operating hour
Subject
① Engine
warning light
and machine
breakdown (1 h)
930E/A30598
Failiure date:2011-12-8
19388
Reason for engine overhaul: Metal chip found in oil pan and high SMR close to 20,000 hours.
② Metal
chipping in
engine and sent
to O/V (24h)
③ Remove
engine and
radiator with
sub-frame (36h)
④ Wait for
engine mount
and can not
install (72 h)
⑤ Install the
new engine and
radiator to
machine (84)
⑥ Dynamic test
and completed
& make record
(8 h)
⑦ Stand by
customer ( 7 h)
Go to work
Engine Remove and Re-Install process
250
225
-24
200
150
①
②
-70
③
④
100
⑤
84
72
50
24 24
1
1
-12
-6
⑥
50% of
Downtime
can be
Reduced
113
72
36
12
2
8
2
0
Actual Downtime
Reasonable Downtime
No.
Finding
1
Awaiting for
engine mount
2
Remove and reinstall is longer
Process
No.
Root Reason
Increase one set engine
mount by Cummins
One face meeting to
Unclear responsibility and
clarify responsibility and
③⑤⑥
lack of positivity
prevent process delay
④
Lack of engine mount in
jobsite
Action
Responsible
Cummins
Customer
Customer
Cummins
KCML
Schedule
Aug Sep Oct Nov Dec Jan Feb Mar
●
●
●
●
○ ○
11
Komatsu 7th GTI
4-5、Machine Troubleshooting Process (GENBA) Root Cause Analysis And Action
Machine
930E/A30653
Failure date: 2011-8-24
Operate hour 15500
Subject
Engine with abnormal noise, LH #4 air valve drop off and damaged and cylinder head damaged
① Engine
warning light
and machine
down (1 h)
② Troubleshooting no
tester(48 h)
③ Found
cylinder head
damaged (36 h)
④ Creating part
order issue TSI
report (1.5 h)
⑤ Waiting for
air compr-essor
car (48h)
⑥ Changing all
of the failed
parts (126h)
Troubeshooting & Repair process
278
300
250
200
①
-24
-24
②
③
-46
④
⑤
-14
⑦
⑥
⑧
126
150
100
50
-54
48
0.5 0.5
24
36
72
48
12
1.5 1.5
116
2
16 2
58% of
Downtime
can be
reduced
2 2
⑦ Waiting for
oil and coolant
to charge power
(16 h)
⑧ Dynamic test
completed and
make record
( 2h )
⑨ Stand by
customer ( 20 h)
go to work
0
Actual Downtime
Reasonable Downtime
Process
Root Reason
No
Awaiting for
No plan for
1
⑤⑦
related equipment
repair job
Troubleshooting
Lack of
2 and remove &intall ②③⑥ positivity and
is longer
experience
No.
Finding
Action
Make plan and prepared
equipment in the advance
To clarify responsibility by
monthly meeting and special
training
Responsible
Cummins
Customer
Customer
Cummins
KCML
Schedule
Aug Sep Oct Nov Dec Jan Feb Mar
Provide 2 sets of
● ●
INSITE software
●
● ○ ○
●
● ○
12
Komatsu 7th GTI
4-6、Appendix
4-6-1、Standard Labor Hours From Cummins
According as
customer experience
and knowledge
Remove and
install Reasonable
hours in AJLcoal
mine:84Hours
4-6-2、Estimated profit loss from machine Downtimes
Item (Productivity )
Actual downtime Hours
Reasonable downtime Hours
Unreasonable hours
Trip/Hours
Production loss (Tone)
Average Profit Ton USD/T
Profit loss(Estimation)
#1 -930E/A30598
225
113
225-113=
112
3
290x3x112/1.8x6=
9,022T
12.3 (2011Y)
110,970 USD
#2 -930E/A30653
278
116
278-116=
162
3
290x3x162/1.8x6=
13,050T
12.3 (2011Y)
160,515 USD
Note:
Density/1.8
Coal:OB/1:6
Exchange rate/1:6.4
13
Komatsu 7th GTI
5、Future Action Plan
In order to ensure the 930Ex 32 units fleet availability of more than 90% and keeping a
good relationship with Customer to increase the customer satisfaction the following
activities are needed and will be monitored.
No
Action
Purpose
Responsible
Schedule
Understanding Job task
•Site Mgr.
•Planner
•Cummins
Every week from
Jan.2012
2
Provide each Machine inspection
data to customer,
Understanding machine status
identify problems and recommend
to prepare the related equipment
for optimization of the facilities.
•Planner
•Cummins
•Customer
Every month
from Mar.2012
3
Provide customer with the
machine downtime report for
improvement to minimize down
time.
Identify problems and
improvement through case study
•Planner&Mgr.
•Customer
•Cummins
Anytime
1
Weekly comunication and
planning with customer‘s
maintenance management
4
Komatsu ICT system(EQP、Web
care etc.) support to customer
Forecasting and reduce down
time and shorten parts lead time
•KCML Service
Dep.
•Planner
Anytime
14
Komatsu 7th GTI
15
Komatsu 7th GTI
Appendix
1、 Improvement point by KCRC Support
2、China Coal 930E Engine OV Plan / Progress
3、Mechanical & maintance training by Cummins
4、Improvement point by Care Project
5、 Planner
16
Komatsu 7th GTI
1、Improvement point by KCRC Support
Front view
Disassemble
Assemble
Inspection
Testing
Reduce 930E Down Time & Operating
Cost,to schedule OV and Reduce unschedule
failure
AJL:
1>、Alternator
2>、Wheel motor/7units
3>、Suspension
KCRC Expansion Project
17
Komatsu 7th GTI
2、 China Coal 930E Engine OV Plan / Progress
China Coal 930E Engine OV Plan /
Progress
2009
Result
2011 Plan
2010-2011/7
Result
Aug
Sep
Oct
8
8
8
8
8
8
8
No. of Swing Eng.
Ready for Use
-
-
4
4
4
4
4
4
4
4
3
4
4
4
4
4
1
0
3
1
4
0
-
0
3
3
0
0
0
0
Unsch OV done
executed Unscheduled OV
(AJL) Total
0
7
0
0
A30533
A30580
A30617
A30645
A30646
A30649
10,800
11,549
11,545
12,407
14,754
14,318
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
33168354
33168349
33168352
33171794
33171820
33171823
9347
9348
9349
9350
9351
9352
9353
9354
9355
9356
9357
9358
9359
9360
9361
9362
9363
9364
9365
9366
9367
9368
9369
9370
9371
9372
A30653
A30656
A30597
A30612
A30616
A30619
A30622
A30624
A30640
A30642
A30579
A30594
A30595
A30596
A30623
A30598
A30610
A30611
A30484
A30485
A30486
A30487
A30490
A30491
A30492
A30493
13,736
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
16,070
17,389
17,599
16,545
16,200
17,618
16,570
17,170
15,031
17,893
17,160
17,722
17,851
18,002
18,801
17,500
17,938
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
2011-05-31
33171980
33172036
33170286
33170711
33170999
33171157
33171288
33171612
33171608
33171627
33170053
33170455
33170080
33170456
33171492
33170617
33170615
33170661
33166262
33165960
33166281
33166181
33166095
33166844
33166838
33166806
Mar
6
No. of OVScheduled OV
9341
9342
9343
9344
9345
9346
Feb
-
OV Plan (20000h)
1st CO
SMR
Jan
-
Sch OV done
Original
ESN
Dec
CEBJ OV Capacity（PS)
Sch OV Plan
Truck Chasis Latest SMR Latest Date
2012 Plan
Nov
1st CO
Date
Sch
/Usch
0
2nd
ESN
11,019
2011-03-12
Usch
33167575
5,957
2010-04-20
Usch
33169971
7,485
2010-01-04
Usch
33173193
12,628
2010-11-13
Usch
33173195
14,133
2011-01-28
Usch
33169019
14,435
2011-04-24
Usch
33164910
16,056
18,994
2011-04-01
2011-07-24
Usch
Usch
33171980
33165980
20,716
2011-09-19
Sch
33167030
3
7
0
0
3
2
4
3
0
0
Estimated
Engine Hrs Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12
As of Today
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
10,800
11,549
11,545
1,388
14,754
14,318
7,779
14,731
15,965
14,182
15,111
14,924
15,423
15,735
15,335
8,585
17,389
17,599
3,917
16,200
17,618
2,437
17,170
596
17,893
1,104
-1,272
17,851
18,002
-1,915
17,500
17,938
18
Komatsu 7th GTI
3、Mechanical & maintance training by Cummins
No
1
2
3
Training
Date
ATB
Projected Completion
20-May-11
Maintenance(A,
Date
B,C Check)
Training
Actual Completion Date 21-May-11
Operation
Training
Coolant Training
Projected Completion
Date
17-Oct-11
AJL
DLT -
21-May-11
22-May-11
21-May-11
21-May-11
17-Oct-11
17-Oct-11
4
5
Insite Training
Operator
Mid Class
Manager

¨
¨
¨


¨
¨

¨
¨
Actual Completion Date
Projected Completion
Date
20 –May-11 20 May.2011
Actual Completion Date 20 –May-11 20 May.2011
Oil and Oil
Analysis
Training
Technician
Projected Completion
Date
17-Oct-11
17-Oct-11
20 May.2011
20 May.2011
17-Oct-11
Actual Completion Date
Projected Completion
Date
18-Oct-11
18-Oct-11
18-Oct-11

Actual Completion Date
6
Projected Completion
Date
Troubleshooting
Onhand Training
Actual Completion Date
From May to the end of this year, totally
eight persons

19
Komatsu 7th GTI
4、Improvement point by Care Project
Before Apr.2011
Now
Only report SMR of
warranty machines
Monthly report SMR of all
Operation machines
Machine Downtime
Make major failure report
of warranty machines
VHMS Data
No major component
change out record
SMR
Record all downtime data
for important model
OV Record
EQP Care
R+M Care
Web Care
Lack of operation machines information
No plan for major component overhaul
Parts lead time was long
1、AJL Basic information collect unit
Follow all major component
Change out history
Have more machines operation information
Make major component overhaul forecasting
Reduce machines down time by scheduled
OV and shorten parts lead time
2、Machines down hours analysis
3、Machines health Monitoring
80
70
60
50
40
30
20
10
0
SMR
VHMS Data
Before
Downtime
Component OV
Now
20
Komatsu 7th GTI
5、Planner’s “Scope of Work”
System
Planner
Web Care
Daily
R+M Care
Monthly
EQP Care
Monthly
KOPEN
Daily
Parts Foreman
Scope of Work
 Initialization and registration of newly delivered machines
into KOMTRAX+.
 KOMTRAX+ data download and upload to WebCARE.
(Daily/Weekly)
 Monitor machine health condition and register to Backlog
sheet if any abnormalities.
 Receive machines downtime information from customer.
 Type downtime and usage data up to template sheet and
upload to R+Mcare, as well as weekly downtime sheet
 Analysis of machine downtime reason using R+M Care and
weekly downtime sheet
 Obtain machine SMR & major component change-out
history from customer.
 Report machine SMR & component change-out history to
HQ service department
 Monitoring & scheduling component OV and advise to SS
manager
 Registration & management of Backlogs using Backlog
Management sheet.
 Advise to Parts Key Person to order the necessary parts &
component.
 Timely open & close work order
 Update SS parts & component stock condition
 Report Customer’s parts & component stock condition to
HQ parts Dept
 Forecast parts consumption in SS
Purpose
To find and report some
abnormalities timely
To monitor trend data for
OV timing optimization
To find machine downtime
reasons and take action for
improvement
To forecast major
component OV timing
To accumulate machines
usage for business plan
To prepare adequate parts
& component
To complete all the job in
timely manner
Transparency of Stock
Condition
To order necessary parts
for SS timely
SS Manager
Conduct SS team to do
the proactive job for
preventing catastrophic
failure
Check machine
performance timely
(Availability/Utilization/
MTBF/MTTR)
Advise to customer for
component OV schedule
Advise to customer for
customer’s parts &
component stock.
Control and manage
work order in progress
Suggest to customer their
own parts stockage
21