Health Condition Monitoring

Condition Monitoring 101
Foundation of a repair-before-failure strategy

Brian Schissler-Boichot
May 15, 2013
Agenda
• Overview of Condition Monitoring

– How it fits into the Maintenance and Repair Process
– What is it (definition)
– Why is it important
• Information Collection and Analysis

• A new approach that combines multiple
elements into one solution
2 / Caterpillar Confidential: GREEN / CONDITION MONITORING — ENABLED BY CAT EQUIPMENT CARE ADVISOR
Mining Equipment Management Strategy
Cost / Hr
Availability + Component Life + Rebuild Cost = Cost / Ton
Maintenance Component Product
Component MARC
& Repair Application Life Quality &
Renewal Management
Process Management Reliability
• Preventive • Mine Design • Component • Rebuild Processes • Designed Life • Market Strategy
Maintenance Guidelines History Mgmt (CRC) • CPI Issues Fix • Rate Development
• Condition • Haul Road • Database • Salvage Processes • Serviceability • Risk Analysis &
Monitoring Management Management (Shop) • Parts Commonality Quantification
• Planning • Payload • Fluid Cleanliness • Facility & Tooling • Failure Reporting • Strategy
Scheduling Management Mgmt • CRC Management Development &
• Repair Mgmt • Training • Removal & • Implementation
• Component Mgmt • Productivity Installation • Financial
• Backlog Mgmt Analysis Management
• Parts Mgmt • GET
• Training Management
• Performance • HSEC
Evaluation
• HSEC
Enterprise Condition Monitoring Definition:

• Proactive process of evaluating equipment and application data inputs to provide maintenance,
component replacement, application and repair recommendations
• Analyzes five data elements – electronic data, fluid analysis, inspection data, repair history and site
assessments – into value-added customer recommendations
• A ‘repair before failure’ approach
Why is Condition Monitoring important?
The objective of Condition Monitoring is to take a proactive approach.
Successful implementation and execution of the process will:
• Facilitate timely and accurate detection of changes in:
Equipment health - Performance & operation - Application severity
• Reduce the number of failures and unscheduled downtime repair events
• Reduce overall owning and operating cost by reducing after-failure
(and more costly) repairs
Data Sources – Electronic Data
Electronic Data Inspections Fluids Machine History Site Conditions
• VIMS® • Spreadsheets • ERP / Work • Haulage

• Product Link • Portal • Cat® S.O.SSM order system Optimization
• Electronic • “Smart Device” Services • Warranty • Fleet
Technician • App • 3rd Party • AS Built Productivity
• 3rd Party information Optimization
• iPad/iPhone
• Machine • Site Operations
• Droid
Specification Maintenance
• HTML5 Advisor
data
• Blackberry • Site
• Component
• Windows Life Data Assessment
Mobile Tool
Why is Condition Monitoring important (cont.)?
Successful implementation and

execution of the process will:
• Have a favorable impact on overall
operation and maintenance costs
• Promote an efficient use of labor
resources
• Improve equipment reliability /
availability
• Improve production and cost per ton
• Provide feedback / assurance that
equipment is looked after
Condition Monitoring:
Foundation of a Repair-Before-Maintenance Strategy
• To avoid problems and failures, you must first be aware that potential
problems exist.
• Maintenance and equipment operation have a significant impact on
equipment health and performance.
• Maintenance is not constant; service providers, suppliers, facilities, etc.
change over time.
• Operating practices change due to personnel rotation and in response to
pressures of meeting production goals.
• Applications change as mines mature. Haul distances become longer
and pits become deeper.
• The total costs of unscheduled downtime / failures can be as much as 15
times that of the scheduled event.
We must address changes.
Condition Monitoring is the means
by which we detect that change.
Condition Monitoring: Gathering Information
Where Do We Get The Necessary Information?
However, most data will fall into the

following five elements:
1. Electronic data
Condition Monitoring
data can come from 2. Fluid management
many sources. 3. Inspections
4. Site conditions
5. Equipment history
Data Analysis Recommendation Action
Gathering Information: Electronic Data
On-machine sensors are
used to monitor and collect
data during operation. This
data is stored for download
and analysis.
• Diagnostics – events, event
recorder, data logger
• Prognostics – trends,
cumulatives, histograms
• Production – payload, Health typically uses diagnostics
cycle time, utilization
Condition Monitoring typically uses prognostics
Gathering Information: Fluid Management
Fluid Management starts with
bulk storage and goes beyond
the sample bottle.
Fluid Management includes:
• Fluid analysis
• Filter cutting
• Particle detection and
counting
• Bulk storage filtration
• Machine filtration and kidney
looping
• Make-up fluids
Gathering Information: Inspections
Inspections are the front line
of the Condition Monitoring
effort. Major Failures
An inspection program
includes:
• Operator inspections /
80%
reports Minor Issues
• Periodic / daily inspections
• Pre-PM inspections
• PM inspections
Inspections should be customized
• Post-PM audits for each machine model and for
• Pre-PCR inspections site conditions.
Gathering Information: Site Conditions
Site conditions such as haul
road maintenance and
effective grade impact
component life.
Site application measures
include:
• Application severity
• Operational effects
• Haul road maintenance
Good maintenance cannot

keep up with poor operational
practices!
Gathering Information: Equipment History
Equipment history aids in
identifying failure and
component trends. This
information should be used to
guide Condition Monitoring
efforts.
Equipment history includes:
• Work order analysis
• Equipment repair history
• Failure analysis
• Failure frequency
• Component tracking
Condition Monitoring: Using Information
Analysis: Turning Data Into Information
A Condition Monitoring
analyst uses data from the
five elements to detect
potential issues.
Resources used by the
analyst include:
• Application guides
• O&M manuals
• Wear tables
• CM Tools
Information Leads To Recommendations
The analyst provides repair,
maintenance and application
recommendations utilizing the
information gained through
analysis and specific site
goals.
Elements of a good
recommendation include:
• Observed values
• Critical limits
• Recommended action Good recommendations minimize downtime,
provide better resource utilization, and
• Assigned priority
lower cost per ton.
Sample Recommendation
Putting CM Elements Together
Bad SOS report

Resample SOS
Low oil
pressure
started 3 injectors found
PM on
the
truck
Recommendations Must Enable Action
CM
HR Backlog
Performance
To enable action, the

recommendations must feed P&S
into the backlog and Repair PM
scheduling portion of the site CI
Maintenance and Repair

process. Component Parts
A good condition monitoring program

will include follow-up to validate the
action taken was successful.
On-board Technology: VIMS Gathers Data
VIMS Data Supports Condition Monitoring
The Cat® VIMS System

collects and transmits
machine data and turns it
Over the life of the VIMS system, we have
into information used to had three basic packages.
track:
• 1995 – 68k Hardware. Download
• Productivity information from machine service ports
or telemetry port only
• Machine performance
• 2001 – ABL Hardware. Improved to
• Service scheduling allow wireless file download
• Trends • 2009 – A4N Hardware. Available on
• Diagnostics 793F and 797F; adds Ethernet
technology
• Equipment Condition
Monitoring
The challenge: Understanding What Customers Value
We Must Understand What Customers Value
Customers are NOT interested in:
Customer Value – created through
- Technology / bits and bytes successful outcomes
- Condition monitoring Customer Value:

- Lower Operating Costs
Customers ARE interested in: - Maintenance costs
- Lower operating costs - Repair costs
- Labor cost
- Increased productivity - Longer Lifecycle
- Improved machine / fleet utilization - Increased Production
- Uptime
- Improved overall efficiency
- Availability
- Improved jobsite management - Utilization
Products should be enabled by:

- Technology
- Process / methodology Value Pools – Caterpillar & Dealer
- Know-how / IP
We Must Understand What Customers Value
Mechanical
Availability + Component Life + Rebuild Cost = Cost / Hr
Maintenance
Component Life Component Product Quality Contract
& Repair Application
Management Renewal & Reliability Management
Process
Increasing Service Capabilities

Asset Management
• Guaranteed cost per ton
Increasing Customer Value • Productivity & CI
Equip. Management
• Guaranteed availability
• Guaranteed maintenance cost
• Predictable availability
• Reduced maintenance cost
PERFORMANCE
Health Monitoring
FAILURE
TIME
We Face Several Challenges with our Existing Offerings
• Multiple products with no clear cut product strategy

STRATEGY
• Consuming resources and not gaining ground (Cat / Dealer)
• Unable to combine elements of CM to make more informed decision
• Data Analysis is labor intensive

CAPABILITIES
• Pockets of knowledge with no way to capture and apply
• Integration into other tools/process
• No way to track recommendations and validate action taken

• Hard to track value and prove benefits – WHY is this important to
CUSTOMER “me”- on an ongoing basis
• Lack of a complete solution (All Cat / Third Party equipment)
Cat PAS CMS The sum of these individual

SOS
MineStar™ products has not provided a
System VIMS Product Link IP
holistic solution or total value
Cat ECA Simplified
Lower Owning
& Operating
Costs
A key enabler to dealer CM services: Partners:

• Combines equipment and application information
• Applies predictive analytics
• Utilizes Caterpillar and Dealer interpretive expertise
• Tracks actions leading to enhanced future recommendations
Key Takeaways
• Many mining companies have adopted a repair-before-failure
strategy to reduce the number of unscheduled downtime
events.
• A well-conceived, fully functional Condition Monitoring plan
to support the timely and accurate detection of changes in
equipment health / performance and operation / application
severity is the foundation of any such strategy.
• Caterpillar and Cat Dealers are uniquely qualified to provide
targeted analysis of Condition Monitoring data and to develop
solutions to reduce downtime.
Fuel Filter Saving
Issue: Fuel Pressure DP was Trending high which caused fuel filter plugging
in the field before PM on SSP00115, & 116 and also causing damaging the
fuel injectors and high pressure fuel pump.
Findings: Wagner ran SOS results on customers fuel tanks and it was
determined that fuel had a high level of ISO particles. Each unscheduled
downtime for plugged filter was two hours of lost production.
Action: Started trending fuel pressure reading from VIMS to determine when
fuel filter were starting be become plugged and their worked with the site to
change fuel filter without causing downtime and lost production. As Wagner is
working with the site to install Caterpillar Bulk Fuel Filtration units at site.
Value (2 machines)
Est. component life loss
5-20% $1,200 to $4,800 in parts
Labor saving is $2,060
Est. Lost Production
.$42,00 per machine
Increase sale of $100K
Data Sources – Inspections

• iPad/iPhone
• Droid
• HTML5 Advisor
data
• Component
Mobile Tool
Electronic Inspection
Data Sources – Fluid Analysis

• iPad/iPhone
• Droid
• HTML5 Advisor
data
• Component
Mobile Tool
Gathering Information: Fluid Management
Fluid Management starts with
bulk storage and goes beyond
the sample bottle.
Fluid Management includes:
• Fluid analysis
• Filter cutting
• Particle detection and
counting
• Bulk storage filtration
• Machine filtration and kidney
looping
• Make-up fluids
Data Sources – Fluid Analysis
Dirt Trapped In Filters
Data Sources – Site Conditions

• iPad/iPhone
• Droid
• HTML5 Advisor
data
• Component
Mobile Tool
Site Training
Warren Cat saved 33 seconds off each haul cycles at their customer site.
High Bias and Rack Event
Issue: On SSP001XX we had high RACK and Bias events which will cause
frame and tire damage.
Findings: Wyoming went and preformed several loaded haul cycles and
determined it they would limit the trucks loaded speed to 28 mph they would
reduce the high Rack events by 30% and would save 4 gallons of fuel per
hour without reducing production.
Action: Wyoming is working with customer to implement these
improvements to the site on all 48 Cat trucks.
Value (1 or 48 machines)
Fuel savings: 31,200 gal. Per year or $78K per year.
Huge improvements in engine life, because of lower fuel burn
per hour. 37days of free fuel a year for the site
If implemented on all 48 trucks $3.7M
Frame repair and labor savings: $10K per year.
Why Condition Monitoring? … What’s in it for Me?
Are we where we need or want to be?
Industry Trends
Today in 5 years Benchmark
70
60
50
% of Work Orders
40
30
20
10
0
Reactive Preventive Predictive Proactive
Survey results - 1998
9 Operator Inspection
9 Field Inspection
9 Pre PM Inspection
Equipment Inspections 9 During PM Inspection
9 Post PM Inspection
9 Pre-PCR Inspection
9 Machine Systems Performance Tests
Fluid Analysis
Electronic Machine Data
Site Conditions / Application

BA C K L O G R E C O R D F O RM
E q u ip . N o : D at e R ef e ren ce N o .
W . O r de r N o .
T y p e of I nspe c t ion : O p e r a to r F i eld P re v e n tiv e M a in t. Oth e r

BA C K L O G R E C O R D F O R M
S ym p t o m :
E q u ip . N o : D at e R e f e r en c e N o .
A c tio n : W . O r de r N o .
S y s te m :
Work Order History & Backlog

1 000 E ngi ne T y p e of 3I nspe c t ionCon
101 T orque : v. O p er a to r S t eerin g
4300 F i eld 7000 B as i c M ac h.P re v e n tiv950
e M0 ai
Vn ar t.
ious Oth e r
1 400 E lec t ric al
S ym
3 000 Tr ans m is sion
4 050 Fi nal Dri v e
pto m :
4 250 B rak es
BA C K7200
5050 Hy d rauli c
5500 T ires
L OS usGp ensRio nsE C O R
7320 A / C
960 D
0 F acF OMR
t ory odifM
.
A c tio n : E q u ip . N o : D at e R e f e r en c e N o .
P r io r ity : U r ge n t N ex t P M W h e n P o ss i ble M o n ito r
W . O r de r N o .
S y s te m : E s t im a t e o f R e p a i r T im e s
1 000 Engi ne 3 101 T orque Con v. 4300 S t eerin g 7000 B as i c M ac h. 950 0 V ar ious
M a c h in e H o urs T y p e of I ns pe Hcr. t ion : O p er a to r M a n H ou rs F ie ld HP r. re v e ntiv e M ai n t. Oth e r
1 400 Elec t ric al 4 050 Fi nal Dri v e 5050 Hy d rauli c 7200 S us p ens io ns 960 0 F ac t ory M odif .
3 000 Tr ans m iss ion
S y m p t o 4m250: B rakes 5500 T ires 7320 A / C
P ar t s R e q ue st
I t em Q u an t it yP r io rity : N um
P art Acb er
tio n : U r g e n tD e s c r ip t io n Ne x t P M P ag e W hen
I t em P o ss
Obibsle
e rv a ti o ns M o nito r
1 E st im a t e o f Re p a i r T im es
3 S y s tem :
4 M1
a 000
c h inEe ngi
H one
urs 3 101 H r.
T orque Con v. 4300MSat eerin
n H oug rs 7000 B asi c M acHh.r. 950 0 V ar ious
5 1 400 E lec t ric al 4 050 Fi nal Dri v e 5050 Hy d rauli c 7200 S usp ens io ns 960 0 F ac t ory M odif .
6 3 000 Tr ans m is s ion 4 250 B rakes 5500 T ires 7320 A / C
P ar t s R e q ue st
7 I t em Q u an tit yP r io r ity
P art
: N um b er Ur g e n tD e s c r ip tio n Ne x t P M P ag e I tem
W hen Ob
P o ss i bsle
e rv a ti o ns M on ito r
8
1
9 3 E s t im a t e o f Re p a i r T im es
10
4
11 M a c h in e H o urs H r. M a n H ou rs H r.
5
12
6
13 7 P a r t s Re q ue s t
14 8 I t em Q u an t it y P art N um b er D e s c r ip t io n P ag e It em O b s e rv a ti o ns
15 9 1
10 3 O rd er N um be r
11 4
12 5
13 6 To olin g, C o ns u m a b le s a nd S up por t E qui pm e nt

L if t Truck 14 L iqui d N 7itr ogen
C rane J ack 8
15
T ire E qui pm ent W as hi ng9
O rd er N um be r
10
R e q u este d by : E s tim a te d A rr iv a l D ate
11
S u p e rv i s o r A p p ro v al 12 P a r ts A r ri v a l Da t e
To olin g, C o ns u m ab le s and S up por t E qui pm e nt
13
K e y p un c h e d OK
L if t Truc k L iqui d N itr ogen
C rane 14 J ac k
T ire E qui pm ent 15 W as hi ng
O rd er N um be r
R e q ue ste d by : E s tim ate d A rr iv a l Da te
S u p e rv i s o r A p p ro v a l P a r ts A r ri v a l D a t e
To olin g, C o ns u m ab le s a nd S up por t E qui pm e nt
K e y p un c h e d OK
L if t Truc k L iqui d N itr ogen
C rane J ac k
T ire Equi pm ent W as hi ng
R e q ue ste d b y : E s tim a te d A rr iv a l Da te
S u p erv i s o r A p p rov a l P a r ts A r ri v al D a t e
K e y pu n c h ed OK
©2013 Caterpillar
All Rights Reserved.
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate
and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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Condition Monitoring 101

Foundation of a repair-before-failure strategy

• Overview of Condition Monitoring

• Information Collection and Analysis

Enterprise Condition Monitoring Definition:

Electronic Data Inspections Fluids Machine History Site Conditions

• VIMS® • Spreadsheets • ERP / Work • Haulage

Successful implementation and

However, most data will fall into the

Data Analysis Recommendation Action

Data Analysis Recommendation Action

Data Analysis Recommendation Action

Data Analysis Recommendation Action

Good maintenance cannot

Data Analysis Recommendation Action

Data Analysis Recommendation Action

Data Analysis Recommendation Action

Data Analysis Recommendation Action

Bad SOS report

To enable action, the

into the backlog and Repair PM

scheduling portion of the site CI

Maintenance and Repair

A good condition monitoring program

Data Analysis Recommendation Action

The Cat® VIMS System

- Condition monitoring Customer Value:

Products should be enabled by:

Increasing Service Capabilities

• Multiple products with no clear cut product strategy

• Unable to combine elements of CM to make more informed decision

• Data Analysis is labor intensive

• Integration into other tools/process

• No way to track recommendations and validate action taken

Cat PAS CMS The sum of these individual

A key enabler to dealer CM services: Partners:

Electronic Data Inspections Fluids Machine History Site Conditions

• VIMS® • Spreadsheets • ERP / Work • Haulage

Electronic Data Inspections Fluids Machine History Site Conditions

• VIMS® • Spreadsheets • ERP / Work • Haulage

Electronic Data Inspections Fluids Machine History Site Conditions

• VIMS® • Spreadsheets • ERP / Work • Haulage

Electronic Machine Data

Site Conditions / Application

T y p e of I nspe c t ion : O p e r a to r F i eld P re v e n tiv e M a in t. Oth e r

Work Order History & Backlog

13 6 To olin g, C o ns u m a b le s a nd S up por t E qui pm e nt

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