ETF Haulage Trucks

Agadir, May, 2013

Advanced Maintenance Systems

Content• Modular Technical Design

• F-1 Pit-Stop System

• Fast Components Exchange

• TRMS: Truck Repair Monitoring System

• Maintenance & Repair Sequence

• Electronic Data Collection Flowcharts:• F-1 Pit-Stop System • Component repairs • Part repairs

• Unique Test Facility For Engines and Axles

• Workshop & Team

• What Automatic Data Processing Enables

• Global Technical Organization

• Summary

Major Components

Conventional trucks: Each size has different major components

(Engine, frame, axles, drive line, tires)

All ETF trucks have the same major components (Power-Modules, Tires & Axle-Groups)

95 % Technical Availability by Fast Component Exchange System!

Maintenance & Repair is done in the Workshop without the Vehicle!

Components are Exchanged and Vehicle Returns to Production within:

15 minutes for Wheels, Power-Modules & Cabins 25 minutes for Axle-Groups

Modular Design

• Modular Technical Design for all Truck Types• Enables Fast Repairs• Enables Container Transport• Considerable Reduction of Spare Parts Stock• More Economical Manufacturing

• Trucks can Continue Production even with a Technical Fault that could

shut down a conventional truck for days!• Engine shuts down: Truck still mobile!• Flat tyre: Truck still mobile!• Wheel-motor defect: Truck still mobile!• Hydraulic defect: Truck still mobile!

• Trucks always able to return to the Workshop• No blocking of Haul Roads, Loaders and Hoppers• No Tow Truck Required

Modular Design Advantages

• Maintenance & Repair is completed in the workshop without the truck!

• Components are exchanged and truck returns to production within:

• 15 minutes for Wheels, Power-Modules & Cabins• 25 minutes for Axle-Groups

• Considerable Reduction of Parts Stock for all Truck Types

• Identical Power-Modules • Identical Axle-Groups

Major Components in Containers

Power-Module Changed in 15 minutes

Unique Removable Power-Module designed for easy Exchange & Maintenance

Axle-Group Changed in 25 minutes

Fast Tire Changes in 15 minutes!

TRMS©: Truck Repair Monitoring System

• All Employees Registrations via Fingerprint recognition

• All Individual Components/ Parts have RFID Tags / Barcodes• For Electronic Data Processing• Avoiding Human Error

• Integrated Preventive Maintenance• Avoiding Unscheduled Repairs

• Technical Status of Components Permanently Monitored• Global Trends in Operational Performance scrutinized by ETF• Immediate Remedial Action taken if necessary

• Automatic Parts Ordering from European Stockholding• Assures Delivery with Shortest Lead-times

• Automatic Warrantee Processing

In Case of Vehicle Fault:

• Message displayed to Operator & Workshop (in the local language!)

• When Convenient to the Operation (not when Hauling on grade, loading or unloading) truck returns to the workshop

• Informed Technicians are Ready with New Exchange Component

• Truck arrives at Workshop; Component is Exchanged

• Truck Back in full Production between 15 and 25 minutes later!Minimal Loss of Revenue!

F-1 Pit-Stop System:

Automatic Tag Readingupon Entrance & Exit Workshop

(Chassis, Power-Modules, Axle-Groups, Cabin, Dump-body & Tyres)

• Automatic Operating Hours Registration of Truck, Components & Tyres• Reduces Maintenance and Inventory Costs• Reduces Human Error

Maintenance & Repair Sequence:

Stage 1: F-1 Pit-Stop System- Major Components Exchange- Enables 95% Technical Availability during Full Life

Cycle

Stage 2: Component Repair- Assures Components Availability

Stage 3: Parts Repair

- Reduces Costs

Stage 1: F-1 pit stop Flowchart:OPERATOR & WORKSHOP

Alerted for Technical Fault by Truck Computer

Technicians log in by Fingerprint and Prepare Exchange Component

Manager assigns Technicians

Truck, Components & Tyres Reading

Truck Downtime Registration Truck Operating Hours RegistrationJob Data on Workshop Monitor

Truck, Components & Tyres Reading

Truck Downtime registrationTruck Operating Hours registrationComponent Operating Hours registrationTyres Operating hours registration

Component Repair Job assignment

Job-Time registration

Truck goes to workshop

Automatic RFID ReadingUpon Truck arrival in Workshop

Prepared Component Exchanged

Automatic RFID ReadingUpon Truck exit from Workshop

Truck returns to Operation

Technicians log out

Stage 2: Component Repair Flowchart:

Component Technical History Update

Component Tested

Component Barcode/RFID Scan

Component returned to Stock

Technician logs out

COMPONENT WITH FAULT With Automatically generated Job number

Technician assigned to Job

Component Barcode/RFID Scan

Fault Diagnosis on Test Equipment

Defective Part Scanned & Exchanged

Job Time registration

Technician logs in by Fingerprint

Component Registration

Part Operating Hours registration New Part sourced from Stock Part Repair Job assigned

To find Defective Part

Stage 3: Part Repair Flowchart:

Part is Tested

PART WITH FAULT with Automatically generated Job number

Technician logs inTechnician assigned to Job

Part RegistrationPart Barcode/RFID Scan

FAULT DIAGNOSIS ON TEST EQUIPMENT

Part Technical History update

Automatic Warrantee ClaimAutomatic Stock UpdateAutomatic Part Ordering

Registration Job TimeTechnician Time registration

Part Barcode/RFID scan

Part returned to Stock

Technician logs out

Part Operating Hours registrationNew Sub-Part sourced from Stock

Defective Part Repaired

A. REPAIRABLE

Automatic Warrantee ClaimAutomatic Stock UpdateAutomatic Part Ordering

Registration Job TimeTechnician Time registration

Technician logging out

Part Operating Hours registrationPart Technical History update

Part Scrapped

B. NON-REPAIRABLE

Unique Test facility for Power-Modules and Axle-Groups

After the repair is completed all components are fully tested Repair errors corrected without additional truck downtime

                                                                                                                              

Workshop design

Workshop roof is equipped with 5,100 m2 of Solar Panels generating between 0,7 & 1,9 MW of renewable energy.

Power, lighting, heating and ventilation costs are kept to a minimum by utilizing this renewable energy.

Workshop & Team

• Dedicated Workshop, Repairs carried out inside!• Guarantees best possible quality and shortest repair times

• Dedicated Team trained for the Trucks and the System• Right mind-set• Qualified for Truck Repair Monitoring System (TRMS)

• Special Tooling and Major Components always on-site:• Power-Modules, Axle-Groups, Tires, Cabins, Body, Tipper

cylinders, Steering cylinders, Hydraulic pumps & motors etc.

• On-site Activities:• All Repairs and Overhauls (mechanical, hydraulic & electronic)

enabled by unique test facility for Power-Modules and Axle-Groups

• Fabrication of Hydraulic hoses• Tire repairs• Body repairs

Automatic Data Processing Enables:

The Client: - Truck Operational Data Registration

- Truck Downtime Registration

ETF Project: - Component & Parts Operating Hours Registration

- 24/7 Updated Stock-list & Automatic Ordering

- Component & Parts Technical History Registration

- Technicians Working Hours Registration

ETF Germany: - Global Monitoring of all Components Exchanges

- Trends in Operational Behavior of Components

RESULTING IN: - Best Possible Truck Performance

- 95% Technical Availability during Full Life Cycle

- Sustainable Quality Improvement

ETF Technical Organization German Headquarter is connected on-line with all Projects World-wide

(24/7/365)

• Global monitoring of all components exchanges and repairs

• Automatically generating parts requisitions from ETF central stockholding

• Trends in operational behavior of components are monitored and immediate action is taken if necessary

• Most Advanced Maintenance & Repair System in the Industry• In Speed• In Quality• In Costs

• 24/7/365 Stock Updating with Automatic Parts Ordering

• Reducing Human Error

• All Parts in Stock in Europe• Shortest Possible Lead Times

PROVIDES:

• Superior Truck Performance• 95% Technical Availability during Full Life Cycle• Sustainable Quality Improvement• Automatic Warrantee Processing• Lowest Costs per Ton

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MODULAR TECHNICAL DESIGN & ADVANCED IT Results in:

ETF: Mining Solutions for the 21st century

Thank you for your attention!

www.etftrucks.eu