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ETF Haulage Trucks
Agadir, May, 2013
Advanced Maintenance Systems
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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
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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)
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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
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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
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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
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Major Components in Containers
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Power-Module Changed in 15 minutes
Unique Removable Power-Module designed for easy Exchange & Maintenance
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Axle-Group Changed in 25 minutes
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Fast Tire Changes in 15 minutes!
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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
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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:
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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
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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
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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
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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
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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
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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
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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.
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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
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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
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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
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• 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:
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ETF: Mining Solutions for the 21st century
Thank you for your attention!
www.etftrucks.eu