This document discusses tools and methods for monitoring the condition and effectiveness of periodic service for machines. It includes a discussion of lubricant analysis programs, vehicle health monitoring systems, and condition monitoring management tools that can help with early detection of issues. Charts are presented analyzing fault codes and magnetic plug readings that demonstrate how condition monitoring data can be tracked over time. Improving parts readiness, tool preparation, and checklists are suggested to enhance periodic service effectiveness by reducing wasted time.

1. Product Support Dept

2. Product Support Dept
ISI MATERI
PERIODIC SERVICE EFFECTIVENESS
CONDITION MONITORING MANAGEMENT TOOLS

3. Product Support Dept

4. Product Support Dept
▪Is the machine that will be in the PS
is ready?
▪Is the man power for the PS is ready?
▪Are the tools ready for PS?
▪Are spare parts for the PS is ready?

5. SOURCE: SPBR team
1 Analysis done for PS III on an HD785 on 3rd May 2012 and PS II on an HD785 on 10th May 2012 with a total of ~20 hours of observation
Workshop wrench time analysis
100 8
3 3
7
2 4
1 11
9
14
39
Tool
finding
Total Break Wrench time
Walking/
chatting
Delay
Waiting
Tool
prepara-
tion
Tool
transpor-
tation
Technical
discussion
Parts
trans port
Parts
prepara-
tion
Incidental activities Non-value adding activities
Delays due to unprepared tools
& equipment
Waste caused to sub-optimized
work processes and parts flow
Idle time due to lack of supervision
14% 13% 35%
Difference in UT’s
mechanics start time
with Costumer
contributes to ~ 1
hour of lost time every
day
4
Potential to
improve wrench
time by 9 % by
preparing the parts
in advance
We can improve wrench time
by 11% by enhancing
supervision of mechanics
Potential to improve wrench
time by up to 14% by
preparing the right tools in
advance and storing them in
an accessible location
1
2
3

6. Product Support Dept
Observation Need Improve
Parts
readiness
• Part should have
been prepared by a
team WPSR and
placed near the
Machine
Tools
preparation
▪ Tools, and mechanics
are all ready by the
time on workshop
▪ Mechanics takes all
the tools needed for
his job in one go
Checklist for
mechanics
▪ One checklist used per job
for all mechanics in the
team
▪ Each mechanics
carries a pocket check
list with them
▪ PS checklist of each
component separately
▪ Parts are not ready when
unit comes in to the bay
▪ Tool box is unorganized and
mechanics takes longer time
to find tools
▪ Mechanics are going back
and forth
to the toolbox to take their
tools

7. Product Support Dept

8. Product Support Dept
EFFECTIVENESS PERIODIC SERVICE
CONDITION MONITORING MANAGEMENT
Tools

9. Product Support Dept
Condition
Monitoring
Management
Tools
Lubricant
Analysis
Program
(PAP)
WEB CARE
(VHMS PLUS)
VHMS
Vehicle
Health
Monitoring
System
VHMS is Activity "Repair Before Failure"
Important Technical Parameters based Monitoring
Trending as a function Early detection of early symptoms
that could potentially cause damage large scale / fatal
The VHMS plus controller monitor the health condition of all
major component and remote analysis of take machine and its
operation. VHMS plus can be monitored by downloading
information direcly from the truck with a laptop, or through
the use of WEBCARE, a satelite communication network, that
allows access to the machine conditions through the internet.
Program analysis to help determine if there were parts of
the lubricating oil wetted components excessive wear,
and also shows the damage to the complement system.

13. 0
20
40
60
80
100
120
140
160
180
200
220
240
11-Jan-11
18-Jan-11
1-Feb-11
12-Feb-11
10-Mar-11
7-Apr-11
2-Jun-11
6-Oct-11
19-Feb-12
24-Mar-12
25-Apr-12
16-May-12
27-Jun-12
24-Jul-12
17-Aug-12
13-Sep-12
HP730E
Sum of IRON - RIGHT
WHEEL MOTOR
Sum of COPPER - RIGHT
WHEEL MOTOR
Sum of ALUMINIUM -
RIGHT WHEEL MOTOR
Sum of SILICON - RIGHT
WHEEL MOTOR
Sum of SODIUM - RIGHT
WHEEL MOTOR
Magnetic Plug Examples
Gear Tooth Conditions Example

15. 215
246
45
81
31 28 28 19 12 11
28
10 12
35
6 6 5 13
57
11
45
4 3 10
49
3
18
17 17
13
12 12
11
10
8 8
5 5
4 4 4 4 4
3 3 3 3 3 3 3 3 3
0
2
4
6
8
10
12
14
16
18
20
0
50
100
150
200
250
300
Unit
Freq
Fault Code
HD1500-7 Error Code as of 5 ~ 12 Mar'2012
Total Freq
Total of affected unit ( QTY )
31 30
14
1
21
16
2 2 2 3 1
11
2 1
9
2 3
64
18
63
3 2
9
24
1 1
8
19 17
11
2
13
1
6
2
64
17
0
35
70
Frequency
4A5XZH & 4A5WZH as of 5 – 12 Mar 2012
4A5WZH: Drop in Steering Accumulator gas pressure 1 4A5XZH: Drop in Steering Accumulator gas pressure 2

16. Product Support Dept