Operational Excellence -TPM in the processes.Mineros Aluvial

November 2021

Crossword

➢ Fila 1: Metodología y filosofía de gestión integrativa yparticipativa que el operador logra detectar a tiempo losproblemas.

➢ Fila 2: Adjetivo, consciencia de las obligaciones durante sucadena de operación en el medio ambiente y comunidad.

➢ Fila 3: Metodología que busca eliminar la causa raíz de unproblema.

➢ Fila 4: Racionaliza u optimiza los programas existentes demantenimiento, historial de fallas y otra información técnica yeliminar defectos.

➢ Columna 1: Actividad económica.

➢ Columna 2: Identifica qué fallas pueden ocurrir en elactivo, circunstancias que llevaron a la falla y luegopreguntándose qué eventos pueden causar que el activo falle.

➢ Columna 3: Objetivo que mejora el estándar.

➢ Columna 4: Acción que produce un efecto.

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Crossword answers

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1 T P M

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N

E 3 4

2 R E S P O N S A B L E

1 I P X

3 R C A E C

C R E

4 P M O A L

C E

I N

O C

N I

A A

L

Generalities

Continuous Improvement's Cycle in the information

3 A´s Management Indicators

Gather data

Analyze theinformation

• QualitativesQuantitatives

IssueJudgments

• Redirectstrategies

MakeDecisions

AUDITABLE

The data must be credible. Both the data and the

analysis must be clear and solid, not complicated

or inconsistent.

ACTIONABLE

The information must show a clear cause-effect

relationship otherwise, they`re vanity metrics.

ACCESSIBLE

Everyone involved in the Project must be able

to consult and understand the information

Robert Anthony Triangle

Holistic Approach Judgment and Decisions

Information

Data

Strategic

Tactical

Operativa

GatherData

AnalyseInformation

IssueJudgments

MakeDecisions

Lagging Indicators, Indicadores Retrasados

ROCE, ROI, EVA, EBITDA

Leading Indicators, Indicadores Avanzados

Customer Service, Conversion Rates

Data to information transition cycle

For making decisions judgment based on facts and not superstitions or hypothesis are required

Hard Savings Soft Savings Virtual Savings Postponed Costs

Reduction of costs of

maintenance

Reduction of losses do to

technical abilities

Reduction of future costs

Availability vs occupation

Improvements in the system

designee

OPERATIONAL MANAGEMENT

DIRECTION MAINTENANCE

ENGINEERS

MAINTENANCE TECHNICIANS

Cascading indicators

KAI´s

KPI´s

KMI´s

KSI´s

Inspection Lubrication

Breakdown, Main Time To Repair,

Mean Time Between Failure, Dowm Time

Availibility

Economic Value Added

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Strategy vs Process indicators

Values

thay govern us

Our

PeopleExcellence

Operational

EVA

“value”

KAI´s vs KPI´s indicators

KAI

KAI

KAI

KAI

KAI

KAI

KPI

KAI

KAI

KAI

KAI

KAI

KAI

KAI

KPI

KAI

KAI

KAI

KAI

KAI

KAI

KAI

Henry Ford

3 Sustainability Pillars and 4 S´SSatisfaction Stakeholders

Outputs: Operational Reliability

(Human, Designee, Process and

Maintenance)

4 S´s (Stakeholders)

3 P´s (People, Profit, Planet)

Information - Decision Making

Imputs:

Methods or Procedures

Mind of Work (3 dimensions)

Materials (MRP)

Machinery (Asset Management)

Base Data or Information

Controls:

BSC (Balance ScoreCard), KSI’s, KMI’s, KPI’s, KAI’s

Maintenance Planning and Programming

Financial and Statistical Tools

Standards or Procedures

Resources:

Specialist (Engineer, Planning, Technicians)

Information System

Technical Information of the equipment

(Record, fails, catalogs, manuals, blueprints)

Benchmark

Total Productive Maintenance (TPM):

✓ Integrative Management Methodology andPhilosophy.

✓ Focus per Process.

✓ Personal Empowerment.

Fuente IM&C Fuente Mineros Aluvial Draga Cucharas

TPM vs RCA, RCM y PMO THROUGHT THE OPERATIONAL EXCELENCE MODEL, MdEO

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Relationship Overall Equipment Effectiveness, OEE-Costs and Opportunity Loss Tree, COLT

Operational Costs

Fixed Costs

Variable Costs

OtherCosts

Availability Efficiency Quality Logistic Stock Proyects

Costs Volume Control

Costs and Opportunity Loss Tree, COLT

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Tree Losses Costs and Opportunities, TLCO

TLCO, Mineros Aluvial

MAQUINAS MATERIALES MANO DE OBRA METODOS TIEMPO

PP MTO

Frentes - Bloques abandonadosRedragadoVoladuras fallasRecirculación del molino

PP AutonomosNPI OperativoPP Operativos

Ausentismo

Averías (NPI)NPI Energía Material humedo

TenorDiluciónBarroMaterial esteril dragas

AccidentalidadHoras ExtrasHabitualidad

Rendimiento (Redragado)

Análisis de falla

Eficiencia (% Recuperación)

EnergíaCombustibleAire Agua

Rendimientos por operadorTOC subterráneo

7 Insumos y repuestosConsumos de bodegaObsoletosOcasionales

TPM 4.0, AtegroupVirtual Reality and Reverse Engineering Applied Cases

Objective: Perform lifting and inspection for the fabrication of a mining bucket.

Machinery manufacturer | www.austineng.com.au

Pilar Early Management and Planed Maintenance Pillars

Objective: Perform lifting and inspection of a mining mill for rubber coating.

Excelence enginering products, wear resistent |www.global.weir

Pilar Early Management and Planed Maintenance Pillars

!Responsable mining in the XXI Century! | www.mineros.com.coObjective:Perform lifting and inspection for the fabrication of the part.

Pilar Early Management and Planed Maintenance Pillars

Security Pillar, SHE and Productivity.

Danger and Risk Assesment Productivity

Root Cause Analysis (RCA)

✓ Methodology that seeks to eliminate de root cause of an associated problem.

Excessive wear on the screw`s threads.

1) Insufficient lubrication on the hydraulic screw (Jackscrew Assembly).

2) The frequency for the lubrication wasn`t the one indicated by the maker.

3) Record of the activity on the EAM but it didn't get done.

Fuente http://www.ntsb.gov/Events/2000/Aka261/jackscrew.htm

TPM vs RCA, RCM and PMO Through the Operational Excellence Model, MdEO

Objective: Capture solid models with precision and real definition of surfaces for it`s reconstruction through revers engineering.

Physical ModelCapture object.

STL Modelresult of 3D scanning. Parametric

CAD Model(tree of operations).

Deviation analisys Metriology

Global CAD vs STL. Machining model

Pilar Early Management and Planed Maintenance Pillars

Objective: create reverse engineering por Surface inspection due to long term wear.

!Responsable mining in the XXI century! | www.mineros.com.co

Pilar Early Management and Planed Maintenance Pillars

3D Scanning Process for mill liners

3D Scanning of the liners

Creating the Polygonal mesh

Deviation analysis

3D Model generation for the

extraction of blueprints

Making the deviation

report

Reliability Centered Maintenance (RCM)

✓ Identify potential failures to prevent them form happening again.

✓ Maintenance plans considering the Operational Context, The Industrial Safety and the Enviroment.

TPM vs RCA, RCM and PMO Through the Operational Excellence Model, MdEO

Planned Maintenance Optimization (PMO)

✓ Process based on the RCM principals and considers this 9 steps:

TPM, RCA, RCM vs PMO

Through the Operational Excellence Model, MdEO

Sept 1: Task compilation

Step 2: Failure Modes Analysis (FMA)

Step 3: Racionalization and Review of theFMA

Step 4: Functional Analysis

Step 5: Appraisal of the Consecuences

Step 6: Define the Maintenance Politicy

Step 7: Review and make into groups

Step 8: Approval and Implementation

Step 9: Dynamic Program

MdEO Mineros ALuvial

Y ( Results)

MdEO = f(Equipment manufacturer recommendations, Maintenance plans records,

Strategic Allies of EAM (Benchmarking), TPM, RCM, RCA y PMO)

Operational Excellence Model (MdEO)

TPM RCM

RCA PMO

RFE

HIS

f(x)

Are the Maintenance Strategys Dependent or Independent?

Operational

Excellence

Budget

ROI, ROAROCE Skills

Business

Excellence

Assets

ExcelenceExcelence of

People

Standards

Excellence in

Security and Environment

Materials

Process

Excellence

Operational Excellence Model Mineros Aluvial, MdEO

Process

Reliability

Processes

ReliabilityHuman

Reliability

Reliability

Design and MttoOperational

Reliability

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OperationalExcellence

Pillar FI Pillar PMPillar Office

Pillar EM Pillar PMPillar

TrainingPillar

Training5 S Pillar AM

Business Excellence

Asset Excellence

Excellence of People

TPM Pillars Supporting the OpEx Model Vs Programs

Pillar SHE

Pillar AM

Excellence in Security

and Environment

Pillar A.M

Process Excellence

Pillar AM Pillar QMPillar SHE

Alluvial Mining Operational Excellence Model, MdEO

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Mineros Aluvial

Perspective aligned to 5 Pillars (Programs)

Operational Excellence Model (TPM) Alluvial Miners

BSC, Balanced Scorecard, EBITDA, Accidents, Cash Cost, etc.

Human Management Programs- Development, Knowledge Management, Climate/Culture

Value Generation

Safety People OSH

SUPER Model DUPONT + ARL SURA

IPM Management

SAP updateEngineering ReliabilityTribology

TPM

5 ESES Operational Reliability

Process Improvement

SINERGIAALQUIMIA

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Quantification of TPM Savings

Focused

Improvements

APCOIndicators KAIZEN

Ideas

Stops

CatalogRCA´s RCM Support PMO

RAM o

CDM

P&P IDM PDM

P&P-Focused Improvements and PDM

You can delegate the Activity but not theResponsibility; you can share the praise but not the guilt.

The Solution to Procrastination, Timothy A. Pychyl.

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