You are on page 1of 32

ORGANIGRAMA DE MANTENIMIENTO MINA CHACHAUATA

Director
Mantenimiento

Planeacin y
Programacin

Palas

Mecnicos (4)

Secretaria

Camiones

Electricos (4)

Mecnicos (6)

Electricistas (2)

MINA CHACHAUATA

Director
Mantenimiento

TOTAL

TOTAL

Secretaria

Camiones

Electricistas (2)

Equipo
Auxiliar

Mecnicos (2)
Electricos (1)
TOTAL

19

Datos de operacin
Consumo combustible
Pala Elctrica
2800 KW/H
Pala Hidrulica
8 gl/h
Camin
10 km/gl
D9L
5 gl/h

Cambio aceite
Reductor
Pala Hca
Camin
D9L

Capacidad
50 gln
60 gln
42 gln
35 gln

Costos
Hora Hombre
Combustible
KW/H
Aceite
Filtros D9L
Filtros Pala Hca
Filtros camin
Repuestos Pala Electrica
Repuestos Pala Hca
Repuestos camiones
Repuestos D9L
300 dias de trabajo al ao

COP$
$ 40,000
$ 4,200 GLN
$ 450
$ 17,000 GLN
$ 250,000 ea
$ 450,000 ea
$ 220,000 ea
$ 281,250,000 ao
$ 37,500,000 ao
$ 1,575,000,000 ao
$ 306,250,000 ao

Mina de cobre Chachauata


Vida del proyecto
Valor ton
Horas trabajo da
Produccin de Cobre
# palas Hidrulicas
# camiones
Vel promedio camin
Ciclo pala
Ciclo camin

25 aos
$ 87,500 COP
18
2
40 Km/hr
5 minutos
5.25 minutos

Produccin de Esteril
# palas
Ciclo Pala
Capacidad camion
Distancia promedio Botadero
Ciclo camin

Cobre
Pala Hidrulica
Camin
Tractor (D9L)
Esteril
Pala Elctrica
Camin

5
2.5 minutos
60 Ton
5 Km
6.00

MTTR
Hrs

(Rata Fallas)
Anual

12
8
6

50
75
150

24
8

36
100

ata
Valor activo
Valor US$
Valor Col $
Pala Elctrica
1,500,000 3,750,000,000
Pala Hca
300,000
750,000,000
Camin
600,000 1,500,000,000
Tractor D9L
500,000 1,250,000,000
Edificio
500,000 1,250,000,000

Mina de cobre Chachauata


Vida del proyecto
Valor ton
Horas trabajo da
# palas
Capacidad Pala
Ciclo pala
Ciclo camin
# palas
Capacidad Pala
Ciclo pala
Ciclo camin
Capacidad camion
# Ciclos camion cobre
# ciclos por camin
# Camiones
Produccin mxima dia

25 aos
$ 87.500 M COP
18
Cobre
2 ea
2 tons
5 minutos
#Ciclos pala da
5.25 minutos
Cap.maxima por pala da
Esteril
5 ea
#Ciclos pala da
20 Tons
Cap.maxima por pala da
2.5 minutos
6.00 minutos
Camiones
60
Cobre
Esteril
Total camiones necesarios
432
2160
205.7142857143
180
2.1
12
14.1
Ton da
Dias ao
Cobre
25,920
300
Esteril
129,600
Real esteril VS Cobr
129,600

Costo
Hora Hombre
Combustible
Produccin hora por pala hca
Valor prod hora por pala hca
Tiempo maximo posible
Tiempo planeado por mantenimien

$ 40 Mil COP
$ 3,500 GLN
720 Ton
$ 63,000 MCOP
5,400
103.68

216

432

hachauata
Valor activo

12,960

Valor US$
Valor Col $
CANT
Pala Elctrica
1,500,000 3,750,000,000
5
Pala Hca
300,000
750,000,000
2
Camin
600,000 1,500,000,000
30
Tractor D9L
500,000 1,250,000,000
7
Edificio
500,000 1,250,000,000
1
8,500,000,000

25,920

Valor total activo

Mxima
produccin annual
7,776,000 tons
$ 680,400 MM COP

vlr TOTAL
18,750,000,000
1,500,000,000
45,000,000,000
8,750,000,000
1,250,000,000
75,250,000,000

Matriz de Mantenimiento actual


Sistema
Pala Elctrica

Clase
Alto Voltaje

Bajo voltaje
Reductores
Sistema mecnico
Pala Hidrulica Pala Hidrulica
Camin
Tractor D9L
Edificio

Camin
Tractor D9L
Edificio
Total

Categora Criticidad Mantenimiento preventivo


13.2 Alta
Inspeccin
Termografa
400 Alta
Termografa
Pin
Baja
Cambio Aceite
Varios
Baja
Inspeccin
2 ton
Alta
Inspeccin
Cambio Aceite
60 Ton
Media
Cambio Aceite
Cat D9L Baja
Cambio Aceite
Varios
Alta
Inspeccin

Frecuencia (Meses)
6
6
12
250 hrs
6
Diaria
250 hrs
250 hrs
250 hrs
1

Horas Parada
Cantidad # Eventos ao PM
CM
Dispon M. Obra(M$) Repuestos Aceite Combustible Costos manto
5
10
240 4320 83.11%
547,200
281,250
828,450
5
10
0
5
5
0
5
10.8
9,180 28,274,400
9,180
5
10
0
2
600
0
2
4.32 51.84 1200 88.41%
100,147
37,500 4,406
320,818
142,054
30
64.8 518.4 18000 88.57% 1,481,472 1,575,000 46,267 2,410,491 3,102,739
7
15.12 90.72 6300 83.09%
511,258
306,250 8,996
659,595
826,504
1
12
2,640,077

2,200,000 68,850 31,665,304

4,908,927

Operacin

900,000

360000
5,400,000
1,260,000

7,920,000

180,000

For ABB internal use only


STRICTLY CONFIDENTIAL

Attachment 7

CALCULO DE COSTOS DE MANTENIMIENTO


EMPRESA
Perodo
Fecha:

Chichicauata
Ao 2007

PRESUPUESTO
Valor

en 1000 $

del prsupuesto

GASTOS DE PERSONAL
Costos directos
Salario
Beneficios
Sub-total
Costos indirectos
Parafiscales
Cargos por Otros beneficios
Sub-total
Total Gastos Personal
Materiales y Repuestos
Materiales
Repuestos
Consumibles
Cargos por costos de manejo de materiales
Total Materiales y repuestos
Gastos directos de Servicios
Equipos y Herramientas
Alquiler (Compra) de equipos
Alquiler (Compra) de Herramientas
Sub-total
Ingeniera, Entrenamiento y Software Prod/Maint
Cargos Internos
Compras y/o servicios
Sub-total
Otros Servicios/Sistemas contratados
Internos
Externos
Sub-total
Total Gastos Directos de Servicios
GASTOS INDIRECTOS
Gastos de Infraestructura
Arriendos
Herramienta especial, Instrumentacin y Equipo Mobil
Transporte / Vehiculos
Oficinas / Suministros de Computo, Hardware y Software
Comunicaciones y Equipos
Salud, Seguridad, Calidad y Medio Ambiente
Administrativos, Legales y servicios de Seguridad (Security)
Sub-total
Otros Gastos
Viajes y Recreacin
Contratacin, Entrenamiento y Retencin
Despidos sin justa causa
Sub-total
Total Gastos Indirectos
PROYECTOS Y/O MODIFICACIONES
OTROS COSTOS ESPECIALES
Costos establecidos por la Empresa, Impuestos y seguros
Garantas de equipos comprados y servicios
Financiamientos especiales, utilidades por bonos, creditos & riesgo seguros
Costos de intereses
Otros
Total de otros costos especiales
Contingencias
Provisiones por riesgos identificados
Provisiones totales

-51.4

2,200,000
68,850
2,268,850

-44.2

0
2,268,850

-44.2

0
0

0
226,885

-4.4

226,885

-4.4

TOTAL COSTOS DE SERVICIOS

5,135,812

-100.0

RESULTADO NETO

5,135,812

-100.0

Cantidad de personal
Personal directo
Personal Indirecto
Total Personal

Page 11 of 32

2,640,077
2,640,077

19
9
28

Services RRC, Attachment 7, 07.29.03

Costo del ciclo de vida de la Pala Hidrulica


Life Cycle Cost Worksheet
<--Yellow Boxes Are For Data Input
Discount Rate (%)-->
0%
Project Life (25 yrs )-->
25
Tax Provision (%)-->
-$24,779,673 <--Net Present Value
<--Internal Rate Of Return

Capital Costs:
Capital Acquisition Costs

0
$3,750,000

Acquisition Costs:
Program Management Costs
Engineering Design Costs
Engineering Data Costs
Spare Parts & Logistics Costs
Facilities & Construction Costs
Initial Training Costs
Technical Data Costs
Documentation Costs
Mayor repairment costs
Annual recuring costs (Maintenance)
Other periodic costs( Combustible)
Operating Costs
Comsecuences Costs
Disposal Costs

$0
$0
$0
$37,500

$37,500

$37,500

$37,500

$37,500

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$60

Savings:
Annual Savings (use positive #s)

NPV & IRR Calculations:

0
1
2
3
4
Capital equipment
$3,750,000
Costs
$37,560
$680,372
$680,372 $2,930,372
$680,372
Savings
$0
$0
$0
$0
Straight Line Depreciation
$150,000
$150,000
$150,000
$150,000
Profit Before Taxes
-$37,560 -$830,372 -$830,372 -$3,080,372 -$830,372
Tax Provision @ 38% Of Profit Before Tax
$14,273
$315,541
$315,541 $1,170,541
$315,541
Net Income can be profit or loss
-$23,287 -$514,831 -$514,831 -$1,909,831 -$514,831
Add Back Depreciation
$150,000
$150,000
$150,000
$150,000
Cash Flow (Net Income + Depreciation)
-$3,773,287 -$364,831 -$364,831 -$1,759,831 -$364,831
Discount Factors @ 0%
1.0000
1.0000
1.0000
1.0000
1.0000
Present Value
-$3,773,287 -$364,831 -$364,831 -$1,759,831 -$364,831
Net Present Value
-$24,779,673 Este es el costo del ciclo de vida de la Pala por los 25 aos del proyecto
Internal Rate Return
<--Requires at least one positive and one negative number in the present value row

EAC

Aos reemplazo
3 -$ 1,204,593
6 -$ 1,045,712
9
-$ 966,918
12
-$ 985,646
15
-$ 965,883
18
-$ 952,708
21
-$ 965,439

25

-$ 991,187

Costos en Miles COP$


38%
ate Of Return
25 aos
5

10

11

12

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$3,000,000
$142,054
$320,818
$180,000
$22,680

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000

$680,372 $2,930,372
$0
$0
$150,000
$150,000
-$830,372 -$3,080,372
$315,541 $1,170,541
-$514,831 -$1,909,831
$150,000
$150,000
-$364,831 -$1,759,831
1.0000
1.0000
-$364,831 -$1,759,831
aos del proyecto
er in the present value row 32

7
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

8
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

9
$3,703,052
$0
$150,000
-$3,853,052
$1,464,160
-$2,388,892
$150,000
-$2,238,892
1.0000
-$2,238,892

10
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

11
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

12
$2,930,372
$0
$150,000
-$3,080,372
$1,170,541
-$1,909,831
$150,000
-$1,759,831
1.0000
-$1,759,831

13

14

15

16

17

18

19

20

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$3,000,000
$142,054
$320,818
$180,000
$22,680

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

13
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

14
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

15
$2,930,372
$0
$150,000
-$3,080,372
$1,170,541
-$1,909,831
$150,000
-$1,759,831
1.0000
-$1,759,831

16
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

17
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

18
$3,703,052
$0
$150,000
-$3,853,052
$1,464,160
-$2,388,892
$150,000
-$2,238,892
1.0000
-$2,238,892

19
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

20
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

21

22

23

24

25

$37,500

$37,500

$37,500

$37,500

$37,500

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000
-$375,000

21
$2,930,372
$0
$150,000
-$3,080,372
$1,170,541
-$1,909,831
$150,000
-$1,759,831
1.0000
-$1,759,831

22
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

23
$680,372
$0
$150,000
-$830,372
$315,541
-$514,831
$150,000
-$364,831
1.0000
-$364,831

24
$2,930,372
$0
$150,000
-$3,080,372
$1,170,541
-$1,909,831
$150,000
-$1,759,831
1.0000
-$1,759,831

25
$305,372
$0
$150,000
-$455,372
$173,041
-$282,331
$150,000
-$132,331
1.0000
-$132,331

$3,750,000

Costo del ciclo de vida de la Pala Hidrulica


Life Cycle Cost Worksheet
<--Yellow Boxes Are For Data Input
Discount Rate (%)-->
0%
Project Life (25 yrs )-->
21
Tax Provision (%)-->
-$21,669,228 <--Net Present Value
<--Internal Rate Of Return

Capital Costs:

0
$3,750,000

Capital Acquisition Costs

Acquisition Costs:
Program Management Costs
Engineering Design Costs
Engineering Data Costs
Spare Parts & Logistics Costs
Facilities & Construction Costs
Initial Training Costs
Technical Data Costs
Documentation Costs
Mayor repairment costs
Annual recuring costs (Maintenance)
Other periodic costs( Combustible)
Operating Costs
Disposal Costs

$0
$0
$0
$37,500

$37,500

$37,500

$37,500

$37,500

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$60

Savings:
Annual Savings (use positive #s)

NPV & IRR Calculations:

0
1
2
3
4
Capital equipment
$3,750,000
Costs
$37,560
$680,372
$680,372 $2,930,372
$680,372
Savings
$0
$0
$0
$0
Straight Line Depreciation
$178,571
$178,571
$178,571
$178,571
Profit Before Taxes
-$37,560 -$858,943 -$858,943 -$3,108,943 -$858,943
Tax Provision @ 38% Of Profit Before Tax
$14,273
$326,398
$326,398 $1,181,398
$326,398
Net Income can be profit or loss
-$23,287 -$532,545 -$532,545 -$1,927,545 -$532,545
Add Back Depreciation
$178,571
$178,571
$178,571
$178,571
Cash Flow (Net Income + Depreciation)
-$3,773,287 -$353,973 -$353,973 -$1,748,973 -$353,973
Discount Factors @ 0%
1.0000
1.0000
1.0000
1.0000
1.0000
Present Value
-$3,773,287 -$353,973 -$353,973 -$1,748,973 -$353,973
Net Present Value
-$21,669,228 Este es el costo del ciclo de vida de la Pala por 8 aos con reemplazo cada 9 a
Internal Rate Return
<--Requires at least one positive and one negative number in the present value row
EAC

-1,031,867.99

Costos en Miles COP$


38%
ate Of Return
8 aos
5

10

11

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$3,000,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$680,372 $2,930,372
$0
$0
$178,571
$178,571
-$858,943 -$3,108,943
$326,398 $1,181,398
-$532,545 -$1,927,545
$178,571
$178,571
-$353,973 -$1,748,973
1.0000
1.0000
-$353,973 -$1,748,973
con reemplazo cada 9 aos
er in the present value row 32

7
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

8
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

9
$3,680,372
$0
$178,571
-$3,858,943
$1,466,398
-$2,392,545
$178,571
-$2,213,973
1.0000
-$2,213,973

10
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

11
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

12

13

14

15

16

17

18

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$3,000,000
$142,054
$320,818
$180,000

12
$2,930,372
$0
$178,571
-$3,108,943
$1,181,398
-$1,927,545
$178,571
-$1,748,973
1.0000
-$1,748,973

13
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

14
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

15
$2,930,372
$0
$178,571
-$3,108,943
$1,181,398
-$1,927,545
$178,571
-$1,748,973
1.0000
-$1,748,973

16
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

17
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

18
$3,680,372
$0
$178,571
-$3,858,943
$1,466,398
-$2,392,545
$178,571
-$2,213,973
1.0000
-$2,213,973

25
19

20

21

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$37,500

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$2,250,000
$142,054
$320,818
$180,000
-$375,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

$142,054
$320,818
$180,000

19
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

20
$680,372
$0
$178,571
-$858,943
$326,398
-$532,545
$178,571
-$353,973
1.0000
-$353,973

21
$2,555,372
$0
$178,571
-$2,733,943
$1,038,898
-$1,695,045
$178,571
-$1,516,473
1.0000
-$1,516,473

Costo anual equivalente


Aos
-$ 1,300,000

-$ 1,250,000

-$ 1,200,000

-$ 1,150,000

-$ 1,100,000

-$ 1,050,000

-$ 1,000,000

-$ 950,000
3
-$ 900,000

12

15

18

21

25

Tiempo
planeado

Relacin entre OEE y Retorno del Capital empleado

5,296

Max prod / h
1,440
Disponibilidad
88.4%
Eficiencia
80.0%

Calidad
100.0%

Prod
Terica
/annual

Valores en MM de COP$

7,626,701
OEE
70.7%
Precio / Unit
0.088

Costo / Unit
0.000

Prod real /Anual


5,394,145

UBruta / annual
471,988

U.Bruta / Unit

Utilidad

0.088

Costo Directo
Mantenimiento
4,909

466,539

Costos fijos/
Annual
5,449

Facturacin
471,988

Margen de Utilidad
98.85%
ROCE

Depreciacion
340

Otros costos fijos


200

Activos fijos
75,250
Costos
operacin
39,585

Facturacin
471,988
Capital
Empleado
114,835

Rotacin del Capital


Empleado
4.11

406.27%