TheSolutionFiles

A Guide to P&H Mining Equipment Inc.

Reliability Centered System Requirements

• Maintainable Electrical and

Maintenance Package Mechanical Systems

Reduce Unplanned Downtime

and Maximize Component Life

Summary Benefits
• RCM is a process that includes: • Higher shovel availability and improved
productivity through:
 Identifying Individual Components
 Reduced Maintenance Hours
 Defining Maintenance Tasks
 Reduced Unplanned
 Specifying Frequencies of Tasks
Downtime
 Outlining Resource Requirements
 Receiving a proactive
 Performing FMEA (Failure Mode maintenance plan
Effect Analysis) focusing on which tasks
 Generating Transferable data from need to be performed
the RCM into customers’ CMMS for each component.
(Computer Maintenance
Management
System)
The Right Task 923

At the Right Time Previous

684 PM
Using the Right People Plans

And the Right Recommendations RCM

Plan

165 55

Tasks
Tasks Hours
Man-hours

continued
Become More Efficient! RCM Recommendation
By implementing Reliability Centered Function Description To raise and lower the dipper to facilitate material movement with an RSL
Maintenance: of 415,000 lbs.
Functional Failure Description Unable to raise and lower the dipper to facilitate earth movement
Perform the Right Tasks for planned Failure Mode Cause Name 01-A-02-Blower brushes worn
downtime as developed from accurate Failure Mode Cause Description Motor brushes worn excessively
RCM recommendations. Failure Effect Description Over time the brushes wear and if not replaced in time, the brush pig tails
make contact with the commutator and cause mechanical damage and or
flashing. The diverter will shut the shovel down. Downtime to replace brushes
Plan downtime at the Right Time based if no damage occurred approximately 2 hours. In the event of damage to the
on customized component life estimates motor downtime may increase to 12 hours (motor needs replacement).
specific to application and environment. Recommendation ID 17-1-1-2-1-1
Recommendation Type RCM
Maximize personnel efficiency by having Recommendation Basis RCM/FMEA Strategy Based
the Right People and equipment available Part Code 1075 Motor, DC-Hoist
during planned downtime. Asset ID 41XB-XXXXX-HST-EL-01
Recommendation Headline Brush Inspection/Replacement
Ensure proper completion of maintenance Task Description Inspect/change motor brushes
tasks by using the Right Recommendations Task Category Maintenance
developed from the RCM process specific Task Type Preventative (time-based PM)
to machine and application, and based Interval 500 HOURS
on OEM recommended maintenance Recommended Resource Electrician
Status ACCEPTED
schedule.
Comments Perform on front and rear hoist motors
Description / Safety Precautions Be sure that the Hoist system, fields and motor heaters are de-energized
and locked out
Analysis Process: Special Instructions 30 brushes required for one complete motor brush change-out. Consider
• The RCM process is based on the use of 10 brushes for each motor or 20 total.
Failure Modes & Effect Analysis, (FMEA). Recurring True
 In the FMEA for a shovel, the analysis Trigger 500.00
Resource Quantity 1
puts each component into one of the
Estimated Man Hours 2
eight functions, Hoist, Swing, Crowd, Estimated Cost
Propel, Dipper / Trip, Air, Electrical, and Manuals Drawings 4100XPB Maintenance and Operators manuals
Lube systems. Special Tools 1. Regulated compressed air supply or vacuum cleaner
 The LCM group has a completed 2. Tape measure/brush length guide
Support Equipment None
RCM Plan for the Electric Mining
Consumables Fine non-conductive sandpaper (#00)
Shovel product line.This analysis can
Required Equipment Status OFF-LINE
be applied to the customers’ geological
conditions to tailor a maintenance plan Sample RCM Plan Maintenance Package for a 4100XPB/C Hoist System
specific to the machine.

Box 310  •  Milwaukee,Wisconsin 53201 USA

www.phmining.com Phone: (414) 671-4400  •  Fax: (414) 671-7306 www.minepro.com
NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any
time without advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of product for any
particular purpose as performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this product.
P&H and P&H MinePro Services are trademarks of Joy Global Inc. or one of its affiliates. © 2009 P&H Mining Equipment Inc. All rights reserved.

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