Joy Global Solutions

8/10/2019 Joy Global Solutions

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Smart Services/PreVail - Remote Health Management

phmsociety2013

By:

Anubhaw Bhushan

Program Manager - Remote Health Management


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29 October 2013 ES-41213 Improvement ProjectLifecycle Management

2

Who Are We?


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3

How Big?


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Integrating Equipment, Information and Service

KnowledgeGeneration and

ContinuousImprovement

Case Management,Escalation and Resolution

Issue Aggregation w/Supporting Data

Sub-System SpecificOdometers

Best Practice

Smart ServiceIntegration

Work Order Generation

Supply ChainOptimization

As Operated TailoredTraining

Machine Inspections

Smart ServiceDelivery

OEE

Real TimeAll the Time

World Class PerformanceThrough Strategic

Partnerships

Mastering Lean MiningMethods

World ClassPerformance

SmartServices

Life CycleManagement

OperationalExcellence

Data Information Direction Results

Results


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-CONFIDENTIAL-

2010

PreVail

2012

Data to Knowledge

2013

Smart Services

Service Centresback to OE Repairs Local Field Service Product training Parts Warehousing Technical Resources Asset Revitalizations

Game Changing Service Offering

Continuous Focus on Improving Operations

2016

Integrated Solutions

Core Joy Global Services

Condition BasedEquipment Monitoring

Operator Scorecards Monthly

Reports/Comparisons

Cost AvoidanceCalculations

Component Tracking

System Workflow Engines-IssueResolution

Global Benchmarking Performance Analysis (OEE) Integrated Monitoring Centers Productivity Analysis & Reporting Customer Portal - Visibility

-Part Locations & Orders

- Equipment and system performance

Global network- Monitoring all equipment

Dispatch people and product Integration with customer monitoring

centers

Smart solutionsglobal network

Integrated work orders- maintenance

- parts orders

Service Life Management

Enabled Machine Wi-FiCommunication

Data Visualization Real- Time Monitoring Remote Diagnostics Integrated Schematics & Parts

Books

Historical Analysis


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PreVail Journey/Architecture/Value Offering


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The Journey of PreVail

20132012201120102009

PreVail enabling

Smart Service

PreVail as a

Subscription

PreVail as a

Product

MaintenanceMaintenance Product

for Shovels on the

Centurion Platform

MachineData

Valuetothe

Customer

ProductionCustom Dashboards

shovel production data

Batch based rules

UndergroundUnderground

Maintenance &

Prognostics

First Continuous Miner

Expanded

FleetFCT, LWS, Drill, Non-

Centurion, JNA

machines

Expert Rules

ScalabilityBalance of Fleet

100s of Expert Rules

100s of machines

Shovels5 Shovels20 Shovels& Miners40TotalFleet80

TotalFleet130


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PreVail Architecture


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Power of Data


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Machines Behavior Hoist Over speed EventTime Stamp

Events

13:29:52.646:Operator ref went down to 0 RPM, the lowering speed continued to increase

13:29:54.033:Armature and Field Currents at current limit

13:29:54.156: Load continued to accelerate to -1094 RPM, maximum motion torque failed to holdthe dipper & contents

13:29:55.265

Hoist over speed fault logged, brakes automatically applied

13:29:57.632:Dipper fell another 5.7 meters before its motion was halted


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Machines Behavior Contd..

Power of Data Trending, Computing, to aid in the explanation of

Machines behavior down to milliseconds interval.


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Machine Health Analysis - Voltage Feed

Scenario 1 PreVail Analysis CBEM Augmentation Competitive Benefit

Mains Voltage

Signature-Weakpower distribution

Trending of mains voltage

trips alarms correlation usedto detect the possible issue

causing downtime

A model built on the historical

data and has triggerednumerous true positive alerts,

leading one of them into a

case study

Faster RCA and corrective action

leading to shorten the trail cable lengthand stabilize the power feed

Use of Expert domain knowledge andpredictive modeling


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Part Malfunction Detection

Scenario 3 PreVail Analysis CBEM Augmentation Competitive Benefit

AirScrub

PlePressure

Trending of the relevant tag and

comparative analysis with its

behavior on other machineshelped identified the issue

A model built on the field

investigation, triggered a true

positive alert and helpedidentified a leaky air regulator

feeding the manifold

Leveraged the globally deployed shovelfleet performance to distinguish between

normal vs. abnormal behavior

Expert domain knowledge used toquickly direct the field reps to take

corrective action.


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Results - Operational Excellence

SIIR = Swing Impacts Index Ratio, BJIR = Boom Jacks Index

Ratio, MSIR = Motor Stalls Index Ration, Index Ratio =

Counts per Operating Hour, CBEM = Condition Based

Equipment Monitoring

152

113

54

1647

18 12 12

September October November December

Brakes related Faults/Warnings

Lube & Air related Faults/Warnings

89%

74%

Capitalized on Operating Practices Refinement

Opportunities

0.00

0.20

0.40

0.60

0.80

1.00

1.201.40

1.60

1.80

1Q-2012 2Q-2012 3Q-2012 4Q-2012 1Q-2013 2Q-2013

SIIR BJIR MSIR

Maintenance Optimization -Faults Reduction Over Last

Two Quarters of 2012

Prescriptive & Predictive Data AnalysisPrescriptive & Predictive Data AnalysisProactiveProactiveData Analysts + CBEM RulesData Analysts + CBEM Rules

Machine KnowledgeMachine KnowledgeAccess to SMEs & EngineersAccess to SMEs & Engineers

Notification/ReportingNotification/Reporting35 FSNs, 48 Weekly35 FSNs, 48 WeeklyTrackers, 12 Monthly ReportsTrackers, 12 Monthly ReportsRecommendations/Corrective ActionRecommendations/Corrective ActionClosing theClosing theLoop with the Mine Site and Field ChampionsLoop with the Mine Site and Field Champions

CUSTOMER ENGAGEMENT MODEL


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Results - Productivity Improvements

0

20

40

60

80

100

0

500

1,000

1,500

2,000

Feb-12 Apr-12 Jun-12 Aug-12 Oct-12 Dec-12 Feb-13 Apr-13

CuttingHrs

RateMine

Average Weekly Hrs and Rate by Month

Average Weekly Rate Average Weekly Hrs

0

50

100

150

200

Feb-12 Apr-12 Jun-12 Aug-12 Oct-12 Dec-12 Feb-13 Apr-13

Avg WeeklyTonnes

(000)

MineAverage Weekly Tonnes by Month

Average Weekly Tonnes

Completed 180 cases

Saved 168 Hours

Rate increase 309 Tonnes per Hour

Value in Tonnes/Year = 1,85 M Tonnes

1,85 MTons * $150/Ton = $277 M

Note: Value calculated on 100Hrs per week at 1500Tons per Hour

0

50

100

150

200

250

300

350

0

10

20

30

40

50

6070

80

90

100

AFC LWS PRS

RateIncreaseTPH

HoursSaved

Cases Hours TPH Increase


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Thank You!

Joy Global Solutions

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