Summary:
Infrared Inspections and Technologies (“IIAT”) is pleased to provide a case study that demonstrates the results of delivering Infrared Analysis Solutions on Hydraulic Excavators. The case study will demonstrate the results achieved supporting a fleet of Hydraulic Excavators where an average fleetutilisation rate of greater than 90% was achieved from new in 2018 to October 2023.
1. Purpose of this Case Study
The purpose of this case study is to illustrate the results achieved by IIAT in increasing the reliability and therefore utilisation of an excavator fleet by delivering monthly infrared inspections on a fleet of 6 Hydraulic Excavators from new. Actual ROI figures in a dollar value has been difficult to ascertain as different organisations apply varying metrics to measure the output of their excavator fleets and the dollar values that are attributed to them.
The main key metrics that are broadly accepted are availability and utilisation.
Hydraulic Excavators
- NEW Machine First Inspection Date Machine Inspection Time Intervals
- Total Hours of Operation since NEW
- Utilisation %
- Total number of Faults Identified by IIAT and Communicated to Customer.
- Types of Fault Categories
Through the above metrics, it has allowed IIAT to work with our customers to measure the Return-on-Investment utilising in house financial data provided by the customer to IIAT that included parts replacement costs as well as both planned and unplanned hours. Because of the confidential nature of these measures, this case study does not outline each machine class specific return on investment.
2. The Workflow Approach Undertaken
The IIAT system addresses the 3 main causal areas of failure and downtime in Hydraulic Excavators, being attachment pin and bush failures (predominately caused by lubrication issues), coolers (hydraulic and engine) and hydraulic system (hydraulic cylinders and valves). IIAT provides a very structured approach that combines long shot qualitative data collection while the machine is operating, as well as close shot quantitative data collection while the machine is isolated during crib breaks, ensuring our customer accrues little or no production downtime.
During the periods, for the Hydraulic Excavators c.1,200 images have been collated providing trending to as many as 45 components.
3. Results
HYDRAULIC EXCAVATORS
The Table Below illustrates the outcome of each machine:
4. Summary
IIAT has delivered similar outcomes by regularly inspecting Hydraulic Excavator and Face Shovel Fleet at 6 sites over the past 10 years. As can be seen above, most of the faults that are identified are in the area of attachment lubrication which historically is recorded at an average of 6.5 faults per machine, per year.
The focus of the program is not just predicting faults, but assisting in moving the clients’ overall maintenance program from a reactive to a predictive state which is achieved by the combination of early identification and prompt execution of remedial action.
The customer from the site above says “The data and recommendations provided by IIAT have allowed us to continually assess tune our machine lubrication systems to achieve optimum reliability, availability and utilisation from these machines”.
5. Additional Customer Successes
To date, IIAT has a data library of greater than 1m data points. This has allowed us to develop and implement bespoke statistical based predictive maintenance programs for many miners. Listed below are examples of miners IIAT continues to partner with.
6. Next Steps
IIAT welcomes the opportunity to discuss further the above case study and what steps could be introduced to ensure any customer is achieving the desired utilisation and return on investment outcomes with their Excavator fleet.
Click the button below to download a copy of the IIAT Hydraulic Excavator Reliability Case Study, and we’ll be in contact to learn more about your needs.
