RS15DT050 Caterpillar Riggs AdvancedEquipmentCare v2

Data and Advanced Equipment Care
Dan Riggs Product Support Consultant

Caterpillar Global Mining
September 24, 2015

A Global Reach
Global reach and presence is unmatched

in the industry
Serve customers in more than 180

countries around the globe
More than half of our sales are outside the

United States
Manufacturing, marketing, logistics,

service, R&D and related facilities along
with our dealer locations total more than Dealers
500 locations worldwide 188 worldwide with more than 126,000
employees
Independent, locally owned
Key competitive advantage
2 / Caterpillar Confidential: GREEN / CONDITION MONITORING ENABLED BY CAT EQUIPMENT CARE ADVISOR Copyright 2012 OSIsoft, LLC. 2
A Broad Range of Products and Industries
Cat equipment more

than 3 million pieces
globally is at work for
our customers on
highways, rail lines,
oceans and rivers, in
forests, quarries, mine
sites and oil fields.
A Great Chapter in Mining
Equipment Management
Equipment Management is the overall management of

site specific processes and activities involved through the
entire life cycle of the equipment.
Top Ten Problems
Top Te n Proble ms
Mean Time To Repair (MTTR)
Av ailab ility (%)
30
30
In flu ence o n Availab ility %
25 25
Influence on MTTR
20 20
15 15
10 10
5 5
0
0
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
To p Sys te m s
Top System s
5 / Caterpillar Confidential: GREEN / CONDITION MONITORING ENABLED BY CAT EQUIPMENT CARE ADVISOR
Repair & Maintenance Process Model
Preventive
Predictive
Condition Based
Proactive Maintenance
The M&R model is based on key concepts of Preventive, Predictive or Condition

Based and Proactive Maintenance to achieve the goal of preserving the primary
function of the equipment while at optimum levels of safety, reliability & cost all
within a repair before failure strategy.
Condition Monitoring Defined
Proactive / predictive 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 conditions
Creates value-added work recommendations for a repair

before failure approach
Customer Value
Increased Planned Maintenance
Condition Monitoring On time PMs, less disruption to shop
Less time in shop
80/20 % scheduled work
Condition 7 hrs Mean Time To Repair (MTTR)
Lower Labor and Parts Cost
Monitoring Reduced contingent damage 3X $$
Reduced emergency parts ordering
Increased Component Lives
Lower cost per hour
Parametric Improved Mean Time Between Shutdown (MTBS)
Change Prognostic 50-60 hrs
Increased Availability
deviation 60 MTBS and 7 MTTR = 90% PA
Predictive Wear Reporting
Minimum Damage
material Monitoring
Performance
Minimum Cost
Planned Downtime Planned
Some Damage Physical
Moderate Cost
Moderate Downtime
Indicator
Reactive
Extensive Damage
High Cost Machine
Most Downtime Alarm
Failure
Weeks Days Hours
Time
Cat Equipment Care Advisor
Dealer offered Condition Monitoring services

powered by Cat Equipment Care Advisor
Analytics Strategy
Machine
Conditions
Association and Compared
Business Rules to a
Standard
Machine
Machine
Conditions
Conditions
Compared
Compared
to Similar
to Itself
Machines
Inputs:
Electronic Data Repair History Fluid Analysis Site Conditions Inspections
Cat Equipment Care Advisor
Know More.
Practical knowledge from
worldwide fleets
Global Caterpillar and Cat
dealer knowledge and expertise
Get More.
Advanced analytics
Maintenance and repair
recommendations
Value tracking
Do More.
Higher availability
Increased productivity
Improved operator performance
Customer Value
Condition Monitoring more effective

Percent Scheduled Work improvement of 5% - 30%
Mean Time Between Stoppage improvement of 10% - 50%
Physical Availability Improvement of 1%-5%
Recommendation value based on saves

Real examples range from $5,000 to $500,000
Value examples
Recommendation Value: $53,600 Risk Avoidance: $73,200
Repair Cost: $19,600
Cat ECA was used to monitor a fleet of 797Fs at a MARC site in Australia. A new C175 engine had just
been installed. Ten days after installation, the Compare to Self analytical model indicated engine oil
pressure was dropping rapidly. The Dealer Condition Monitoring Analyst sent a recommendation to site
suggesting a possible turbo failure and/or possible fuel dilution. Recommended boost test and cylinder cut
out test be performed, as well as another engine oil sample.
Result: Boost pressure test indicated no issue, technician pulled oil sample and did on site viscosity test
and determined the root cause to be a leaking upper injector seal that was causing fuel dilution and
engine oil pressure degradation.
Value examples
Recommendation Value: $33,907 Risk Avoidance: $45,322
Repair Cost: $11,415
A 793D at a site in South America experienced 3 different
exceptions that were all related: engine fluid result with high
soot and iron, exhaust temperature differential trend and
exhaust temperature compared to self. Possible causes were
dead injector, wiring harness fault, or boost leak. Condition
monitoring analyst sent a recommendation with two
knowledge articles, one for inspecting for harness fault and
one for inspecting for lash on valves and injectors.
Result: Inspection revealed an injector damaged by a misaligned pushrod. The pushrod was replaced
along with the damaged injector and rocker on the LH bank causing higher RH exhaust temperatures.
Value examples
Recommendation Value: $465 Risk Avoidance: $592,479
There was an engine oil filter pressure differential on an off-highway truck that was not enough to trigger on board
alert, but was discovered by Cat ECA because the rate of change was abnormal. Dealer Condition Monitoring
Analyst looked at fluid sample results, which were good, and saw last PM was done less than a few hours before
this issue was flagged. Dealer sent recommendation to site to pull engine oil filters and look for blockage. Local
technician inspected filter and found plastic covering for the filter inside the filter housing. Inaction would have
eventually restricted enough oil flow to scuff a bearing, potentially leading to engine failure.
Recommendation Value: $576.16 Risk Avoidance: $5,500
There was a brake pressure low exception found by Cat ECA from a comparison of the local fleets rear brake
system pressures. Cat ECA also noted an exception in this trucks rear brake pressure from a long term trend
analysis. In these situations, the normal course of action by maintenance is to reseal the hydraulic slack
adjuster. However, the Dealer Condition Monitoring Analyst looked at data logger information and discovered
erratic pressure sensor signals. He instead told the site to replace the sensor and not the slack adjuster. This
avoided unneeded additional downtime , repair labor, and parts.
Caterpillar Value
True VOC on how equipment is being utilized
Seamless transition of product improvement into
Engineering
More efficient CPI and NPI process
Taking Equipment Management Solutions to Market
Supplying the Customer his data of equipment location and what its doing with
remote, real-time information
Supplying the Customer the ability to manage his equipment with health and
utilization trends compared to benchmarks via automated reporting.
Supplying the Customer condition based recommendations to make informed

decisions about managing and maintaining machines.
Supplying the Customer PM Planning / Scheduling and Repair Execution based

on the M&R processes, Component tracking and planning, Parts execution
planning, Operation application consulting, Operator training, and CI support
Supplying the Customer empowerment of Cat Dealers to proactively manage

equipment so they can focus on their business.

RS15DT050 Caterpillar Riggs AdvancedEquipmentCare v2

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Data and Advanced Equipment Care

Dan Riggs Product Support Consultant

September 24, 2015

Global reach and presence is unmatched

Serve customers in more than 180

More than half of our sales are outside the

Manufacturing, marketing, logistics,

Cat equipment more

Equipment Management is the overall management of

The M&R model is based on key concepts of Preventive, Predictive or Condition

Proactive / predictive process of evaluating equipment and

Analyzes five data elements: electronic data, fluid analysis,

Creates value-added work recommendations for a repair

Dealer offered Condition Monitoring services

Condition Monitoring more effective

Recommendation value based on saves

Recommendation Value: $576.16 Risk Avoidance: $5,500

True VOC on how equipment is being utilized

Seamless transition of product improvement into

More efficient CPI and NPI process

Supplying the Customer condition based recommendations to make informed

Supplying the Customer PM Planning / Scheduling and Repair Execution based

Supplying the Customer empowerment of Cat Dealers to proactively manage

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