Productos y Servicios de Modular

Administracin
de flota

Navegacin
asistida

Gestin de
mantenimiento

Infraestructura de red
Servicios de soporte

Servicios de
consultora

Herramientas
de gestin
de seguridad

Case Study
How the ProVision Shovel System Works

Digline displaying
real-time shovel
progress

Equipment pitch and

roll indicators

Material polygon
indicating ore type
by color

Elevation gauge
displaying actual
against plan
Current design
surface
GPS-selected
material type
Operator-selected
material type

The ProVision Shovel system guides operators in real

time without the need for manual survey.

Mobile application
Project information (ramp creation)

Mobile application
Elevation control/Grade (side view)

Aseguramiento de la Capacidad mediante el Monitoreo

Event Handling / Snapshots / Trending Minecare

Equipment Condition

P-F Interval

Potential Failure
(detected)

Trend
Alarm 1 Trend
Alarm 2 Trend
Alarm 3

Repair

OEM
Alarm /
RT Monitor

LOW

F
Functional
Failure

HIGH
CRITICAL
PRECISION

PREDICTIVE

Minimum
Performance
Level

PREVENTATIVE

Complete
Failure

RUN TO FAILURE

Time
Permitir la identificacion temprana de la degradacion de salud de un
Activo para minimizar la falla de equipos y componentes

Web Access
MineCare home page

ModularReady Interfaces

Modular provides the most comprehensive interface options in the industry

Over 100 and counting

Case Studies
Reduce Engine Failures and Cut Maintenance Costs on Haul Trucks
A MineCare customer shares how they protect
haul truck engines and turbochargers from
catastrophic failures with effective use of
real-time data, avoiding $750,000 in
maintenance costs in just a few months time.

The real-time proactive features of the

MIneCare system are directly attributable
to reducing turbocharger failures, resulting
in significant maintenance cost savings at
our operations.
- Corporate Reliability Advisor

CASE 1:
Low Horsepower on Komatsu 830E Haul Truck

CASE 2:
High Exhaust Temperatures and Temperature
Differential

CASE 3:
Low Boost Air Pressure

Case 1
Low Horsepower on Komatsu 830E Haul Truck
After the MineCare system signaled a low
horsepower alarm, the maintenance team
responded to find broken bolts on the haul
trucks rear turbocharger.

Potential Cost Avoided:

$288,000

Low horsepower event triggered from the

GE interface in the MineCare system

When turbo housing bolts fail,

intake pressure is lost as the
housings begin to separate

Case 2
High Exhaust Temperatures and Temperature Differential

Hose that detached from

the turbocharger and
aftercooler.

Potential Cost Avoided:

Following a high exhaust temperature alarm received by the
MineCare system, the maintenance team quickly diagnosed a
turbocharger failure in progress and shut down the truck to
prevent catastrophic engine failure.

$188,000

Case 3
Low Boost Air Pressure
The MineCare system
received alarms
indicating both a low
boost pressure and an
abnormal exhaust
temperature from a
haul truck.

Potential Cost Avoided:

$280,000

The dismantled turbochargers

turbine vanes are exposed,
showing the damage they suffered
during the incident.

Case 4
Reduce Haul Truck Fuel Consumption
A MineCare customer shares how minor
modifications to operator behavior during the
dumping cycle can generate significant fuel
savings.

CASE 4:
Achieving fuel savings by eliminating
excessive engine throttle during dumping
The MineCare system enabled us to improve
more than just equipment reliability,
identifying and correcting operator behavior
that wastes fuel.
- Corporate Reliability Advisor

Case 4
Data Capture & Analysis
Using empirical analysis, it was discovered that average fuel consumption rate nearly
doubles when engine speed increased from 1500 to 1900 RPM.

Average fuel consumption rate nearly

doubles when engines speed jumps
from 1500 RPM to 1900 RPM

Case 4
Theoretical Fuel Savings Estimation
Assuming an average fuel price of US$1.21/L, the expected range of savings for this
customer is between $100,000 and $335,000 per year. This demonstrates that a relatively
simple exercise in researching operator behavior can translate to real and substantial
annual cost savings.

Maximum Annual Fuel Savings

per Truck:
3844.2 L

Potential Cost Avoided:

$335,000

Case 5
The ROI of Proactive Maintenance
A Modular customer shares how they realized
a return of months, not years, on their
MineCare system investment.

OBJECTIVE:
To reduce maintenance costs and downtime
by predicting haul truck component failure

The MineCare system supported

maintenance cost savings of more than
$1 million through the active monitoring
and management of our mobile equipment
assets, not including lost production time.
- Aaron Carter, Asset Health Specialist

Case 5
Methodology
After analyzing 22 months of maintenance data experts discovered a total of 125 maintenance
activities could be classified as saves.
A failure cost recovery factor was applied, considering the remaining component life and its
warranty value, the probability of failure, and the probability of detection by another means.

A MineCare customers cost savings demonstrate the sustainable

opportunity of a proactive maintenance organization.

Case 5
Results & Conclusions
The total adjusted savings are just 12% of the worst case avoided
costs after the failure cost recovery factor was applied. This very
conservative model still produces an annualized savings of $14,680
per truck, which translates to a return on their MineCare system
investment of less than 1 year.

UPDATE:
The customer reported greater acceptance and refinement of
their proactive maintenance processes reporting increases of
their annualized cost savings figure to $53,760 per unit
monitored in 2010 and $80,000 per unit monitored in 2011 using
their failure cost recovery factor.

Cost Avoidance is not considered true accounting dollars, but we

know from our savings that a couple large saves with the MineCare
system immediately pays back the purchase of the system.
- Modular MineCare customer

Year 1&2 Potential

Cost Avoided:

$14,680
per truck/year

Year 3 Potential
Cost Avoided:

$53,760
per truck/year

Year 4 Potential
Cost Avoided:

$80,000
per truck/year

Nuestras ventajas competitivas

Extensa experiencia
en los productos

Experiencia
global

Presencia
local

Comprometidos
con la satisfaccin
del cliente

Caso de Estudio #1
Auditora de Sistema mina de hierro
Revisin de
configuracin y
prcticas operacionales

Reduccin de mensajes y excepciones

tarde en un 80%

Simplificacin de cdigos de fuera de

servicio: de 468 a 80

Cambio en el proceso de reabastecimiento de combustible de

basado en horas a basado en
demanda

Caso de Estudio #2
Administracin del
Cambio
mina de carbn
Optimizacin de la
productividad en
transporte de material

75% de reduccin en espera de

camiones en planta de carbn

Equivalente a 650 horas adicionales de

camin en un mes

El ahorro de camin completo!

Caso de Estudio #3
Mapeo de procesos
operacin oil sands

Establecer un
entedimiento comn de la
forma correcta de hacer
las cosas

Procesos definidos en 12 reas claves

Alto involucramiento y compromiso de

todos los participantes

Mapas de procesos usados para

entrenamiento y administracin del
cambio

CASE 4: Long-time DISPATCH Customer Realizes Training Benefits

Total Tonnes by Month

The Challenge
Prior to training, dispatchers thought they could
beat the system by using manual reassignments
to maximize productivity.

2.26%

After training, they made limited manual

reassignments, relying instead on the DISPATCH
systems proven haulage optimization algorithms.

Loads per Shift

Loads per Shift

2000

Crew 1

Normalized Tonnes*

The Solution

Crew 2

1800

Crew 3
Crew 4

1600
Pre-Training

Post-Training

Month
* Tonnes normalized to truck ready-hours, haulage speed and haulage distance on a per-shift basis

CASE 4: Long-time DISPATCH Customer Realizes Training Benefits

Total Tonnes by Month

The Challenge
Prior to training, dispatchers thought they could
beat the system by using manual reassignments
to maximize productivity.

2.26%

After training, they made limited manual

reassignments, relying instead on the DISPATCH
systems proven haulage optimization algorithms.

Loads per Shift

Loads per Shift

2000

Crew 1

Normalized Tonnes*

The Solution

Crew 2

1800

Crew 3
Crew 4

1600
Pre-Training

Post-Training

Month
* Tonnes normalized to truck ready-hours, haulage speed and haulage distance on a per-shift basis

2.26% increase
In haul truck productivity in just two months.
An increase in over 11,200 tonnes per shift.

Ms informacin:

Modular Mining Systems, Inc.

products@mmsi.com
www.modularmining.com