Availabilty & Utilization Reliability (MTBS) Mean Time to Repair MTTR

100 100 7
Availability MTBS MTTR

90 Utilization Target 6 Target

80
Target MTTR w/o Delays

M TBS (hours)

M TTR (hours)
80 5
60

%
70 4
40
60 3

50 20
2

40
January March May July SeptemberNovember 0 1
January March May July September
November January March May July September
November
February April June August October December
February April June August October December February April June August OctoberDecember

Maintenance Ratio MR Major Drivers

0.6
MR

0.5 Target
Labor/Op. hours

0.4

0.3

0.2
Major Actions
0.1

0
January March May July September November
February April June August October December

GENERAL PERFORMANCE METRICS

kpis
 Tiempo Promedio entre Servicio (MTBS) 793C
Tiempo Promedio entre Reparaciones (MTTR) 793C

80 7
6

HORAS
60
5

Horas
40 4
3
20 2
1
0 0
EN FE M AB M JU JU AU SE O N EN FE MA AB MA JU JU AU SE OC NO
E B AR R AY N L G T CT OV E B R R Y N L G T T V
MTBS 50 45 48 41 43 31 40 38 31 40 42 MTTR 3 2 2 2 4 1 2 2 3 1 1
Objetivo Max 80 80 80 80 80 80 80 80 80 80 80 Objetivo Max 6 6 6 6 6 6 6 6 6 6 6
Objetivo Min 60 60 60 60 60 60 60 60 60 60 60 Objetivo Min 3 3 3 3 3 3 3 3 3 3 3

Dispersión de Servicio

400

350

300

250

200

150

100

50
 PROBLEMS. DISTRIBUTION PER SYSTEMS

Shutdowns per System

Influence on Reliability Influence on Reliability (MTBS)
Last 6 Months
30 40
Engine
27.0%

% of influence per System

25 XMSN/TC

Overall M TBS (hours)

7.0%
30 Diff/Finals
5.0% Engine
XMSN/TC 20 Electrical
9.0% 4.0% Dif/Finals
Frame
Electrical 15 20
Frame Hydraulic
Hydraulic
4.0% Tires Tires
10
PMs
8.0% Others 10 PMs
5 Others
25.0%
11.0%
MTBF Trend
0 0
July August September October November December
December 199x (last month)

Shutdowns per Systems Influence on Turnaround (MTTR)

Influence on Turnaround Last 6 Months
40 7
Engine

% of influence per System

7.0% 7.0% 6 XMSN/TC

Overall M TTR (hours)

12.0%
8.0%
Engine
30
5
Diff/Finals

Electrical
PROBLEMS. DISTRIBUTION PER SYSTEMS
10.0% XMSN/TC 4 Frame
Dif/Finals
Electrical 20
Hydraulic Cost per System
Frame 3
Hydraulic Tires December 199x (Last Month) Cost per System
1.0%
Tires 2 Last 6 Months
PMs
PMs 10 35
28.0% 17.0% Others Others Engine
1 XMSN/TC
30 Diff/Finals
MTTR Trend 9.0% 7.0% Electrical
10.0% 0 0 3.0% Frame
25

% of Total Cost
July August September October November December Hydraulic
20.0% 8.0% Engine Tires
XMSN/TC 20 PMs
Dif/Finals Others
December 199x (last month) 4.0%
Electrical
Frame 15
Hydraulic
5.0% Tires 10
RELIABILITY (MTBS) & TURNAROUND (MTTR) INFLUENCE PMs
Others 5
13.0%
31.0% 0
July August September October November December

Downtime per System Systems Influence on Availability

December 199x (Last Month) Last 6 Months
60 100
Engine

% of influence per System

50 XMSN/TC
17.0% 80
Diff/Finals

Availability (%)
10.0% 7.0% 40
Engine 60
Electrical
6.0% XMSN/TC
Dif/Finals Frame
2.0% 30
Electrical
40 Hydraulic
Frame
Hydraulic 20 Tires
4.0% Tires
23.0%
PMs 20 PMs
Others 10
17.0% Others
14.0% 0 0 Availabilty

Fallas y costo por sistema

July August September October November December
Goal
Months

COST & AVAILABILITY INFLUENCE

 Backlogs Quantity Blogs > 30 Days (% of Total)
Estimated Time to Repair 240 Ton Truck Fleet
240 Ton Truck Fleet
400
240 Ton Truck Fleet 100
Quantity 1000

Executed 90

800

Dow ntim e (hrs)

300
80

Q uantity of BL

Percentage %
600 70
200

60
400

100 50
200
40

0
April June August Octuber December 0 30
April June August October December
May July September Noviember April June August October December
May July September November
May July September November

Backlog Status Backlogs per System

240 Ton Truck Fleet
100

3.24
80
0.590.77 Engine
2.4 1.47 Electrical
Transmission
Hydraulics
Percentage %

60 0.93 2.44 Steering

Air Sys.
PM
Tires
40 Differential
Final Drives
3.04 1.35 Brakes
20
Suspensions
1.03 F.W heels
Fire Sup.
Accidents
0 4.11 3.04 Air/Cond
April June August October December 0.65
May July September November

Situation Analysis
- The Benchmarks or Targets for Quantity, ETTR will be established. It is noticeable the increase of Backlogs and estimated time to repair them (ETTR).
This is very dangerous; we have to improve our reaction (clean BL List). The Nbr. of BL executed is low and constant. The quantity of Backlogs waiting for
being process is affected by the location of the warehouse. The BL waiting for parts are affecting directly on the age of them, BL (>30)
Corrective Actions
- Considering the amount of BL "ready to go" (Green) we will start scheduling more BL within the planned activities and instructing the supervisors to
increase the use of the window of opportunities of the unscheduled repairs.
- We are working in the relocation of the warehouse.
- We will increase the scheduling of BL and the shop will be instructed to executed 100 % of the planned jobs.

baklogs
 Training Hours per System
Total Training Hours (Year) 300
Engine

250 XMSN/TC

Diff/Finals
24.3% 200
32.1% Electrical
Engine

Hours
XMSN/TC
Dif/Finals 150 Frame
Electrical
Frame Hydraulics
Hydraulic
Tires 100
8.4%
Tires
PMs
Others
PMs
8.5%
7.9%
50
4.2% Others
14.7%
0 Total Hours
January March May July September November
February April June August October December Target
Months

% of Redo
Results Analysis

14 Target

12 % Redo

10
% Redo

Outstanding Performance
8

4
Contribution to support Maintenance Operation
2

0
January March May July September November
February April June August October December
Months

TRAINING
Entrenamiento
 Warehouse Parts Stock / Truck Warehouse - Supplier Service Level
100 80
Target
80

Parts Delay (hours)

Warehouse
90

Stock / Truck (US$)

Service Level (%)

60 Supplier
60
80

Thousands
Parts

Parts + Comp.
70 40
40

60
20 20
50

0 40 0
January March May July SeptemberNovember January March May July September
November
February April June August October December February April June August October December
Months Months

Parts Stock. Distribution per System.

40
Situation Analysis
Engine
Xmsn/TC
Diff/Finals
Electrical
30
% of Total Stock

Frame
Hydraulics
PMs
Others
20

10

0
July August September October November December
Months

PARTS

Repuestos
 Fuel Consumption Torque Stall RPM Blow By
Engine Eng7 Engine Eng7 Engine Eng7
200 1800
440

180 420
1750
400

cu feet/hr
160

Lts/hr

RPM
380
1700
140 360

1650 340
120
320

100 1600 300

1000 3000 5000 7000 9000 11000 13000 1000 3000 5000 7000 9000 11000 13000 1000 3000 5000 7000 9000 11000 13000
Hours Hours Hours

Oil Consumption Oil Pressure SOS Results

Engine Eng7 Engine Eng7 Engine Eng7
0.2 500 50

40
0.15 450

ppm of xx
30
Lts/hr

kPa
0.1 400
20

0.05 350
10

0 300 0
1000 3000 5000 7000 9000 11000 13000 1000 3000 5000 7000 9000 11000 13000 1000 3000 5000 7000 9000 11000 13000
Hours Hours
Hours

Component Hours: 14500 Component ID: Eng7 Installed on: Eq.#7 PCR date: January 199x

Evaluation Results

Recommendation

COMPONENT CONDITION MONITORING

Predictivo
 PROBLEMS. DISTRIBUTION PER SYSTEMS

Shutdowns per System

Influence on Reliability Influence on Reliability (MTBS)
Last 6 Months
30 40
Engine
27.0%

% of influence per System

25 XMSN/TC

Overall M TBS (hours)

7.0%
30 Diff/Finals
5.0% Engine
XMSN/TC 20 Electrical
9.0% 4.0% Dif/Finals
Electrical Frame
15 20
Frame Hydraulic
Hydraulic
4.0% Tires Tires
10
PMs
8.0% Others 10 PMs
5 Others
25.0%
11.0%
MTBF Trend
0 0
July August September October November December
December 199x (last month)

Shutdowns per Systems Influence on Turnaround (MTTR)

Influence on Turnaround Last 6 Months
40 7
Engine

% of influence per System

7.0% 7.0% 6 XMSN/TC

Overall M TTR (hours)

8.0% 30 Diff/Finals
12.0% 5
Engine Electrical
10.0% XMSN/TC 4 Frame
Dif/Finals
Electrical 20
Hydraulic
Frame 3
1.0% Hydraulic Tires
Tires 2 PMs
PMs 10
28.0% Others Others
17.0% 1
MTTR Trend
10.0% 0 0
July August September October November December

December 199x (last month)

RELIABILITY (MTBS) & TURNAROUND (MTTR) INFLUENCE

8 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

 PROBLEMS. DISTRIBUTION PER SYSTEMS
Cost per System
December 199x (Last Month) Cost per System
Last 6 Months
35
Engine
XMSN/TC
30 Diff/Finals
9.0% 7.0% Electrical
3.0% 25 Frame

% of Total Cost
Hydraulic
20.0% 8.0% Engine Tires
XMSN/TC 20 PMs
Dif/Finals Others
4.0%
Electrical
Frame 15
Hydraulic
5.0% Tires 10
PMs
Others 5
13.0%
31.0% 0
July August September October November December

Downtime per System Systems Influence on Availability

December 199x (Last Month) Last 6 Months
60 100
Engine

% of influence per System

50 XMSN/TC
17.0% 80
Diff/Finals

Availability (%)
10.0% 7.0% 40
Engine 60
Electrical
6.0% XMSN/TC
Dif/Finals Frame
2.0% 30
Electrical
40 Hydraulic
Frame
Hydraulic 20 Tires
4.0% Tires
23.0%
PMs 20 PMs
Others 10
17.0% Others
14.0% 0 0 Availabilty
July August September October November December
Goal
Months

COST & AVAILABILITY INFLUENCE

9 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING