maintenance costs reduction strategy presentation
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R&M and Power Costs analysis and Reduction Strategy
Aim -23% reduction in overall R&M and Power Costs in the region
How
Reduce rate of breakdown – spares quality and correct use of the machine
Use of quality spares at the right price –eliminate the middleman
Accountability – machine ownership scheme (artisan + operator)
Moving towards Total Productive Maintenance –reduced workshop labour from 34 to 23 and sawmill R&M from 43 to 25 @ 06/2012
Key skills retention and training schemes –toolbox scheme
Charter Mobile Equipment Age Distribution
1 1
2
1
1
1
1
2
1
2
1
5
3
1
5
1
2
1
2
0
2
4
6
8
10
12
1 2 3 4 5 6 7 8 9 10+.
Telleloggers Skidder FE Loaders
Haulers MAN Tractors
Fire Tenders Roads
• 77% of 34 production mobile equipment is 4 years old
• Maintenance cost increases with age
Focus on
61%
33%
6%
FY12 Mobile Equip R&M Costs-Actual
Spares Tyres Oils
• Spares
• Quality- rate of
replacement & quality of repair
• Price
• User -reduce
need
• Tyres• Correct spec tyre
for the operation
• State of roads
Major Costs & Strategy
0
2
4
6
8
10
12
14
actual2010 actual 2011 actual 2012 Budget2012 budget2013
Target
Mobile Equip R&M for Plantation($/Ha)
Plantation($/Ha)
• Budget cost• 4 new tractor
engines
• 1 fire tender gearbox
• Target -25% reduction -$13 -$9.8/Ha
• Strategy• Partially rebuild
engines –too old for new engines
• Replace the old tractors in FY14
Major Costs & Strategy
0
1
2
3
4
5
6
7
8
9
10
actual2010 actual 2011 actual 2012Budget2012 budget2013
Target
Mobile Equip R&M for Harvesting($/m3)
Harvesting($/m3)
• Budget cost• 3 new Tellelogger
engines
• 3 new hauler engines
• 4 new Walking Beams
• Target – 30% reduction $9.12 -$6.38/m3
• Strategy
• Spread engine replacement over 2 yrs
• Cover with rebuilds @ a cost 20% of new
0
0.5
1
1.5
2
2.5
3
actual2010 actual 2011 actual 2012Budget2012 budget2013
Target
Mobile Equip R&M for Sawmill($/m3)
Sawmill($/m3)
• Budget
• 1 new FE Loader engine
• Focus on strategies to eliminate FE double handling at the deck to save on fuel consumption
0
5
10
15
20
25
actual2010 actual 2011 actual 2012 Budget2012 budget 2013 Target
Sawmill R&M ($/m3)
Sawmill R&M ($/m3)
Sawmill R & M costs Reduction Strategy
Aim -30% reduction in R&M cost from $10.51 to $8.4/m3
Labour utilisation – moving towards TPM….50% reduction in units
Integration of first-line maintenance personnel into production teams
Reliability cost -rate of breakdown
Spares quality –at least 60% reduction in premature bearing collapse when we fitted SKF bearing in the plant
Adhere to the planned maintenance schedule
Equipment ZESA grid instability protection – reduce the rate of electric motor rewinding
Quality of repairs work to reduce rework -retain and train key skills –PLC; SCADA; High Voltage Switchgear Services
Spares cost Buy quality from the manufacturer –eliminate the middleman
Transport cost –Lathe & Milling Machine on site will reduce the cost machined spares sourcing by at least 2 Mutare-Chimanimani-trips cost
0
2
4
6
8
10
12
14
actual2010 actual 2011 actual 2012 Budget2012 budget 2013 Target
Power($/m3)
Power($/m3)
Power Costs Reduction Strategy
Aim – 27% reduction in power cost from $8.71 to $7.5/,3
Spilling engine generator Consistently run in grid mode @ 450kW – 40% of sawmill power need @ $0.05/kWH
compared to ZESA @ $0.13/kWH & diesel generator @ $0.32/kWH
Timely spares procurement to reduce its down time
Power Factor monitoring-maintain it at unit
Maximum demand management- Daily checklist in place
Lighting cost –phase-out and replace ordinary light bulbs with equivalent
energy savers in the Region
FY12 Structure
34
Engineer
WkshopSupt
Autoelec+ Asst
3 mechs
5 Svcmen
Welder Chghand
Svcman
Bike mechTrailer mech
3 tyrefitters
WkshopClerk
Project Welder
Planner23 heads
Workshops FY13
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