Our haulage fleet is experiencing issues with the quality of our tubs, specifically with the lack of penetration in the welds leading to splitting or cracking in our trucks. To address this, we are considering major rebuild work to enhance the tubs for underground operations and improve their reliability. This includes reinforcing the rear of the tubs for prolonged wear and installing a top strip along the tub's length on both sides to prevent material from causing damage between the layers. The dilemma we are facing is whether to invest over 40 hours of additional labor and materials to rectify the issue and request a design change from the OEM, or focus on training our operators to handle the tubs more carefully to prevent damage caused by loaders. Our fleet is experiencing a high rate of vehicle damage, such as broken frames, mirrors, windows, steps, and rails, leading to an availability rate of only 85 percent. We are seeking suggestions on the best approach to address the damage problem and maintain the fleet's operational efficiency. How can we effectively tackle this challenge and prevent future issues with our tubs and trucks? Any insights or recommendations would be greatly appreciated.
When assessing damage costs in underground mining operations, it is important to consider whether the costs are higher than expected due to the challenging conditions underground. It is crucial to determine if the operators have sufficient experience and knowledge to prevent potential damage. Additionally, evaluating the quality of weld penetration and the impact loads on the welds is essential to avoid overloading. Implementing Total Productive Maintenance (TPM) has been successful in reducing damage on surface mining loaders, but it requires time and effort to see results. It is important to identify the root causes of the damage and explore various solutions to address them effectively. For more targeted advice, please provide additional information about the specific situation.
Quote: Originally shared by Dusted: I am facing an issue regarding the quality of tubs installed in our haulage fleet. These dual-skinned tubs have welding issues with lack of penetration, leading to splitting and cracking in all our trucks. To ensure reliability, significant rebuild work is required to elevate them to underground standards. Any responsible individual would approach the truck manufacturer with this concern. If they have other fleets performing the same tasks for other companies without encountering such issues, it is essential to address the problem with the welders and operators. If the original equipment manufacturer (OEM) cannot provide evidence of their equipment being used more effectively elsewhere, it may be wise to consider exploring alternative options. Research which manufacturer your competitors are using and engage with them for insights. If changing OEMs is not feasible, inform your current manufacturer that you have explored other options and are earnest about seeking improved quality. Money is a crucial factor; therefore, leverage this to your advantage. Instead of simply requesting funds to repair a truck, present options - the cost to repair it versus the additional cost to invest in trucks that do not require repairs. Make a strategic decision.
Thank you for the responses. Unfortunately, another tub has been damaged since my first post. The operators are causing damage faster than we can repair it. The welding on the tubs does not properly penetrate the inside, leading to the issue. I would like to present the problem, but I am concerned about potential incrimination. Both the operators and the product quality seem to be contributing factors to the damage. I will consult with the OEM for their input and look into training options to review underground procedures.
Regarding your dilemma, I believe a two-pronged approach might be the most beneficial in the long run. Firstly, investing in quality improvements and reinforcement of your tubs for underground operations would substantially reduce the risk of future damage and improve the overall availability rate of your fleet, which I see is a current concern. Secondly, supplementing this with operator training to better handle the tubs could further minimize the damage to other vehicle components. It's always helpful to remember that while technical modifications are crucial, the human element is often critical in such operations. This approach would promote not only the lifespan and productivity of your fleet but also the safety of your operators.
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Answer: - The fleet is experiencing problems with weld quality, specifically lack of penetration leading to splitting or cracking in trucks.
Answer: - The fleet is considering major rebuild work to enhance tubs, including reinforcing the rear for prolonged wear and installing top strips along the tub's length on both sides to prevent material damage.
Answer: - The dilemma is whether to invest in design changes and additional labor or focus on training operators to prevent damage caused by loaders.
Answer: - The fleet is facing damage like broken frames, mirrors, windows, steps, and rails, leading to an availability rate of only 85 percent.
Answer: - Suggestions are needed on the best approach to address the damage issue and prevent future problems with tubs and trucks to maintain operational efficiency.
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