As many as 80% of the production fleet consists of mining trucks. Many of them operate almost continuously, up to 6000 hours or more per year, and are worn until their disposable lifespan at one location. To optimize large capital investments in order to purchase a machine / unit, its economic age should be extended to 10 years or more. This equals 60,000 hours or more of its productive age. The key factors that affect the life cycle costs of components include:
1. Component Age
The average component age determines how many times an overhaul or replacement should be made during the productive (economic) life of the machine. This replacement includes replacement of worn, broken, or scheduled replacement parts. Key factors in component age include application load level and component maintenance methods.
Example: a hose that cracks with age
Figure 3.3 Getas / fragile on hose
2. Quality of Component Reconditioning
Rebuilding the main components is a complex and complicated process. The process of rebuilding the components must be done carefully so that the life of the components produced can be maximum. The following procedures have made significant progress as an ongoing effort to improve the quality of the rebound component:
- · Rebuild processes and procedures
- · Contamination control
- · Cleanliness of workshop
- · Performance testing procedures
Figure 3.4 Clean workshop
3. Components Re-Component Cost
The cost of replacement parts and labor costs determines the direct cost of component overhaul.
4. Component Replacement
The ability to reuse expensive parts during a thorough repair cycle determines when those components are no longer economically viable to be reconditioned, and when they should be replaced with new or remanufactured components.
Figure 3.5 New pump (left) and remanufacturing (right)
5. Component Release and Installation
Figure 3.6 The right job is done by a trained factory technician
The wrong method of removing and installing components is a major cause of the high cost of components that are often overlooked. The process of disposing and fitting of the wrong components often leads to worn or worn components prematurely. The disadvantage of rebuilding the component technology lies in the quality of processes and procedures used in the discharge and installation of components of the machine / unit. The process of component release and installation is an important step that is often overlooked.
The process of disposing and installing the wrong components can waste time, cost, and effort devoted to rebuilding high quality components becomes meaningless. Based on experience, poor release and installation procedures are a major cause of premature component breakage and short component life. Applying good installation and disposal procedures is essential for component life and can reduce costs.