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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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!