Constructed and implemented an enhanced Maintenance Management Operating System (MMOS) for FMS Diesel Mobile Maintenance (3)

Early Shift Inspections and Effective Inspections Programs

Maintenance

Mining and Metals

Mexico

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Keywords

MOS
Availability
MTBF
MTTR
Performance Management
CMMS Data Improvement
Effective Inspections
Bad Actor Management
Shift Change Management
Work Management Process (planning)
Supply Chain Stockout Alarm System
Pre-PM
PM Routines
SMART PM
5´s
Pit Stop Green Flag System
Flexibility Matrix

Driver Goal

To improve efficiency, predictability and reliability within the Mobile Maintenance area and equipment.
To improve Maintenance planning and operational effectiveness.
The delivery of the training and coaching required to enable the changes in behavior needed to ensure the sustainability of the operational improvements.

Results
Up to Week 16

Achieved Short range drilling availability to 93% for June. 9 points above the target, and long range drilling availability to 87% for June. 3 points above the target.
Achieved MTBF 17 hours for June. 5 points above target.
Early Shifts Inspection Program has generated 44 minute average of additional potential scoop utilization.
3.33% of real utilization for Scoops generated by improved shift management initiatives.
Stablished a 40 min std effective inspections.
Achieved 100% lubrication compliance for drills for the first time and 100% for scoops for 3 weeks.
Manloading has raised to 77% avg. from 40% before generating 700 MH avg of real executed hours.
100% Pre-PM and Perfect PM compliance for equipment.

Issue
Formal Pre-Op Inspection workflow process and inspection-lubrication procedures varied in how executed. Mechanics were not fully loaded at the beginning of their shift after 7:00 toolbox meeting, and did not have goals or reasonable expectation standard times for an effective inspection.

Solution Approach
Early Shift Inspection Program (ESIP) was installed by achieving anticipated shift change starting time (5:00) for a crew of 3-4 persons, including the supervisor, specialist and 1-2 mechanics. This approach contributed to gain additional potential utilization for operations and to have more productive work hours per day on planned inspection and lubrication work orders by mechanical Maintenance crews. Wrench time improved by having more time on tools by the outgoing mechanic crew. ESIP evolved into an effective inspections program with standard times for scoops lubrication.

Actions Taken

Early shift start from 7:20 to 5:00 am has generated daily average of 3 Scoops ready before 7:45 according to the Shift Startup Mine Process.
Introduced improved inspection checklists for better operator and mechanic first interaction.
Early shift inspection tracker installed to ensure reliable starting and finishing inspection times.
Introduced the concept of effective inspections checking on the quality of them.
Both programs have contributed to an immediate Work Requests increase made by maintenance supervisors, leading into an improved information system for equipment diagnose and potential failure analysis.
Installed a Daily Compliance Effective Inspections and Lubrications for Drills
By using this tool and the activity reinforced by Fernando Palacios, Chief of Diesel Maintenance, achieved 100% lubrication compliance for drills for the first time and 100% for scoops for 3 weeks.
Effective inspections also covered a quick project result, which has been the increase of reportability from the operator to the mechanic. We have a better interaction between operations and maintenance: Every day there is an interaction between the operator and the mechanic at the moment in which the equipment is left for inspection. Fresh and recent information from the operator, allows the raising of more timely warnings with the precise diagnostic elements to attack the root problem.