I am in search of valuable resources and information regarding effective component rebuild strategies for our facilities running similar equipment. Despite implementing different approaches to component rebuilds at each location, we have not witnessed significant availability improvements following major rebuilds based on manufacturer life cycle recommendations. As a result, we have started using oil sampling to gauge when component replacements are needed. However, parts availability has become a major challenge since 2008, with lead times as long as 50 weeks for major items. This issue has prompted us to reconsider our current practices for our CAT/Elphinston LHDs from Australia.
If you have identical equipment operating at multiple plants and their operating conditions are similar, consider implementing the longest maintenance interval for each type of equipment initially. This approach allows you to make informed decisions based on real-world equipment performance. It would be beneficial to track Failure codes and technician feedback on equipment condition during preventive maintenance (PM) checks. By analyzing the number of consecutive "No problem, acceptable" PMs, typically three, you can determine when it's appropriate to extend the PM cycle.
If you are considering overhauling the condition of your LHD's, I highly recommend conducting a thorough assessment of the major components. It's important to assess your resources to determine if you will encounter any issues with garage space or available labor. Additionally, ensuring you have an adequate supply of spare parts is crucial. By anticipating which components will be needed and when, you can proactively manage maintenance requirements. Based on our analysis of various mining equipment, we have found that vendor-recommended lifespans are often conservative. In some cases, the actual lifespan of equipment exceeds what the vendor suggests. This valuable insight is based on data collected from sites where equipment is used until it fails, demonstrating the importance of a comprehensive review of preventive maintenance, life cycle costs, and spare parts management. If you need assistance with your LHD fleet, our team of PMO consultants with extensive mining experience in the USA is here to help. A comprehensive review typically takes about a week to complete. Feel free to contact me at steve@omcsinternational.com for further discussions. Visit our website at www.reliabilityassurance.com for additional resources and information.
What is the meaning of LHD? Are rebuild and overhaul synonymous in this context? In my opinion, rebuilding entails fixing something that is already broken, while overhauling typically involves a process that may be prone to human errors, whether due to original equipment manufacturer guidelines or the condition of the equipment.
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Thank you for your feedback. The issue we face with equipment overhauls is significant, especially considering our underground location and logistical challenges. Limited historical data makes it difficult to determine the appropriate life cycle for our major components. While OEM recommendations may be conservative, waiting for signs of degradation poses risks. If we delay maintenance too long, we could lose valuable core credits, impacting costs significantly. I am currently evaluating the advantages and disadvantages of both approaches to develop a tailored plan for our unique circumstances. Quantitative analysis is essential for making informed business decisions, although the complexity of the issue means there may not be a definitive solution. Our strategy will prioritize cost reduction and improved availability, recognizing the need to address variables that may not be easily quantifiable.
Generally, having an effective preventive maintenance plan is crucial to ensuring your equipment lasts its full lifecycle. You made a smart move with oil sampling as it's an excellent early-warning system for potential issues. Now, as for the availability issues of parts, you could consider sourcing aftermarket parts from reliable third-party manufacturers. They can often provide similar quality at lower costs and shorter lead times. However, always make sure to thoroughly verify their credibility to avoid subpar parts. Additionally, don't overlook the adoption of a predictive maintenance strategy, with the use of IoT devices and data analysis to foresee failures before they occur. This could increase machinery uptime and save on urgent replacement costs. Technologies like 3D printing are also slowly revolutionizing the manufacturing supply chain and could be an option for critical spare parts that have long lead times.
I understand your frustration and the challenges you're facing. I'd suggest reaching out to resources like trade magazines or forums dedicated to industrial machinery maintenance, as they often provide useful insights on effective rebuild strategies. Having faced similar issues, I found that adopting a proactive and predictive maintenance strategy, instead of a reactive one, helped a lot. Additionally, you might benefit from building relationships with secondary suppliers or exploring aftermarket parts to overcome your parts availability issue. The CAT/Elphinston LHDs are quite common, so finding third-party suppliers shouldn't be that difficult. Also, consider stocking up on critical parts in times of shorter lead to mitigate future shortages.
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Answer: - Consider exploring alternative suppliers or aftermarket parts options to reduce lead times. - Maintain close communication with suppliers to stay informed about availability and potential delays.
Answer: - Implement predictive maintenance techniques such as oil sampling to accurately assess the condition of components and plan rebuilds accordingly. - Consider extending the life cycle of components through comprehensive maintenance and monitoring practices.
Answer: - Evaluate the actual performance and condition of components rather than relying solely on manufacturer life cycle recommendations. - Collaborate with maintenance experts and engineers to develop customized rebuild strategies tailored to your specific operational needs.
Answer: - Share best practices and lessons learned among different facilities to streamline component rebuild processes. - Standardize maintenance procedures and documentation to ensure consistency and efficiency across all locations.
Answer: - Explore inventory management strategies to stock critical
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