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ISSN 1747-146X
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THE LEADER VOLUME 11 • NUMBER 11
Global rebuild popularity
Two factors in particular, though there are others, have come together such that the industry is seeing a significant rise in the number of rebuilt machines in use in mines around the world. The first is a general very strong improvement in the quality of machines; better materials are used in their construction and they are built to last longer( in the case of many manufacturers with a view to future rebuilds). The second factor is the long period of depressed markets that we are now, hopefully, coming out of. This has meant rebuilds are a more economic option than new machines, for which mines have been unable to justify the cost.
Many manufacturers are seeing this trend and let’ s look in more detail at Caterpillar, which is an excellent example. Its 793 has been a very successful large mining truck, with thousands in use around the world. It is an industry workhorse, recognised for high productivity and low cost per tonne. It leads the 240-250 ton( 227 t) class with mechanical drive.
Cat ® offers various rebuild standards on this truck and many of its machine types. In an example of the trend to greater numbers of rebuilds, Caterpillar reports just 100 Cat Certified Rebuilds( CCRs) in 2005, by 2010 it was up to around 300 units, but by 2015 this number was up to 900 CCRs. And, twice as many rebuilds that year( some 1,800 machines) were the more basic level of customised rebuild.
Cat says it offers the“ broadest range of options” in rebuilds,“ matched to each customer’ s exact need by machine.” This rebuild program is“ customisable and responsive to any situation.” CCR is the highest level of machine rebuild offered. It is a complete rebuild process endorsed by Cat and only performed by Cat dealers, to likenew condition. Following core exchange, before or after failure, it involves 7,000 new, remanufactured or reconditioned parts. Only genuine Cat parts are used. The dealer may perform salvage operations. Critical engineering updates are incorporated( upgrades optional). The CCR means the customer can expected the rebuild to perform like a new machine – new in appearance and operation.
Cat explains that if“ you repair before failure you are taking advantage of the value built into Cat parts, which are designed to last multiple lives. If you let parts progress to failure, you could be spending as much as 2.5 times more for the cost of your repair. Another problem is potential contingent damage that could be caused to other parts— parts that typically don’ t need replacing.“ When you do let parts progress to failure, Caterpillar studies show that nearly 90 % of the time those failures could have been prevented.”
The CCR is recommended for mines that desire a full second life from the machine. Cost( excluding machine core) typically runs a little more than 50 % of a new machine price and will be carried out urgently to minimise fleet downtime and keep availability at a desired level.
The same can be expected of a Custom Dealer Rebuild, which is tailored to customers’ requirements – core exchange, before failure.
For mines needing less than a full second machine life, the cost will be below 50 % of the cost of a new machine and can embrace Cat certified powertrain and hydraulic rebuilds, with system level / warranty / upgrades.
There is also the Certified Component Rebuild of engines and / or transmissions and torque converter combinations.
Basic Repair and Adjustment extends life before failure using 100 % new parts as required to be replaced and will cost less than 25 % of the cost of a new component.
The Time and Material Overhaul also extends component life. Enhanced reuse and salvage of parts will result in a lower price, which could be anything from 25-50 % of the price of a new machine, depending on what is required.
Cat’ s machines are built to be rebuilt. So many parts are reusable, and backed with an excellent warranty.
Two interesting 793 rebuild examples are Boliden’ s Aitik copper mine in Arctic Sweden and Freeport McMoRan’ s global fleet of those trucks. The Boliden fleet has been rebuilt by dealer Pons and the mine is very pleased with these trucks, considering them to be“ as good as new.” To date all five 793Bs( including one watertruck) and five 793Cs have gone through a CCR. Of the 12 793Ds, six have recently gone through a CCR and another one is under rebuild right now.
Freeport keeps rebuilding its 793s and is targeting 150-170,000 hours out of each truck over a number of rebuilds. These rebuilds are being performed by multiple Cat Dealers located close to Freeport’ s operations wherever they are located in the world.
We all know this is a cyclical business and as we have seen in previous downturns, the industry and its suppliers both take pain, but work together to get through to the next‘ boom’ cycle.
There was an air of cautious optimism at MINExpo at the end of September. Many exhibitors reported having an excellent show with high quality visitors – most were very pleased. Let’ s hope this continues – unlike in 2012!
John Chadwick Founder john @ im-mining. com
NOVEMBER 2016 | International Mining 3