How the use of Life-cycle costing can drive the correct maintenance (in different economic conditions) on large mobile assets and help customers save millions

CIM Vancouver 2010
Abstract During a detail RCM analysis the question about the best maintenance tactic always arises? Do we repair or replace, what will be the best predictive task, is it worth doing, what are we trying to prevent, etc, etc….. In most cases these questions can be answered by the subject matter experts in the room following the steps in the RCM methodology. It is normally true for a given operating condition.

But what if the commodity prices fluctuate or what if operations slow down? Does the same maintenance tactic still apply? Maybe we should consider a different approach when the conditions change. Do we have two maintenance programs that should apply with the different conditions? If so, what is the tipping point?

A recent study on a large mining shovel revealed some interesting facts about changing operating conditions and how the changing commodity price could drive different maintenance tactics. The RCM study revealed that maintenance of an expensive component is still required based on the characteristics of failure. The life-cycle costing model and simulation revealed that the planned maintenance should be adjusted (from on-condition, to scheduled component replacement to doing nothing at all) based on the commodity price and operational conditions. It further revealed a possible saving of approximately $11.0 Mil over the life of the asset if the correct maintenance tactic is followed. The delegates will learn that maintenance is considered based on criticality - whether the failure matters or not (which is a function of the operating conditions). Also, the frequency or type of maintenance is selected based on the failure characteristic (and not criticality). The delegates will further learn how to determine the "ideal spot" for changing maintenance tactics and that "more maintenance does not mean better".
Keywords: Mobile equipment, Failure consequences, Shovels, Life-cycle Costing, Reliability Centered Maintenance, Failure characteristics, Haul Trucks
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