Modular introduced the mining industry to Real-Time Maintenance Management in 2004. Since then, we have continued to evolve the MineCare system as the industry realizes the benefits of real-time data, predictive data, and failure analysis data collection. The MineCare system enables improvements across every area of the maintenance management process, providing the information and tools necessary to respond to, track, document, research, resolve, and predict mobile equipment health issues. Maintenance efficiency requires a knowledge of repair procedures and equipment health indicators, coupled with an understanding of the mine s production targets. Reliability requires a commitment to research, analysis, process, and failure elimination. The MineCare system empowers you to achieve these goals. It allows maintenance personnel to store and standardize procedures, and prevent equipment failures that result in excess and unplanned costs. Improve equipment availability, increase production, and reduce maintenance costs.
Feature Benefit OEM alarms Notification of component minimum performance Remote real-time monitoring helps avoid expensive repair costs and downtime Remote diagnosis while equipment is operating Proactive detection of potential equipment maintenance problems Detection of improper operation of equipment Trending Predict potential failures Event Notifications (configurable alarms) SQL database, Microsoft Reporting Services Engine Independent of fleet management system Integrated with DISPATCH system Supports operational and mechanical KPIs Time Tracking by component, root cause analysis Replicated operational and historical site data Unified view of OEM and user-defined alarms Corporate/Regional-level comparison of data and reporting Reduction of potential catastrophic component failure Progressive alarm values Data collection for Reliability-Centered Maintenance (RCM) and Root Cause Analysis (RCA) Assist proactive planning Data across fleets/operator Customize alarm criteria Define thresholds/parameters Proactive warnings Review by fleet or equipment unit Identify potential failure trends by fleet or unit Simplified storage and management of multiple data types Standard platform for report creation Real-time maintenance management option for customers without the DISPATCH system Monitor operator performance, location/position, status Validation of real situations Less manual data correlation Consolidation of operations, location, and OEM data Identifying poorly performing machines Calculate Mean Time Between Failure (MTBF) Provide knowledge to improve operational practices Comprehensive handling of down equipment events Single-screen summary of equipment status & location Associate OEM alarms to actual maintenance activity Consolidated data sets from multiple sites to allow high-level reporting and analysis User-friendly interface for quick and easy diagnosis Corporate standardization of best-practice maintenance procedures MineCare Deployment Options Standalone Standard Enterprise 2 MODULAR MINING SYSTEMS, INC.
Event Handling Application The Event Handling application allows you to view and process abnormal OEM events. These events come from OEM health monitoring devices, such as Komatsu KOMTRAX Plus, Caterpillar VIMS, or GE Statex among others, and user-defined trend events from condition-based monitoring statements. For example, when using MineCare Standard or Enterprise, you can receive an event when a particular haul truck is moving at a speed higher than 30 mph (48 kph), or when it is loaded with more than 200 tons (181 tonnes) of material and is located near a certain beacon. When an abnormal event occurs, a notification appears. Event notifications include important information about the event, such as the location, operator, and status of the equipment when the event was generated. Notifications can also include potential causes for the event, troubleshooting guides, and links to the equipment manual (which must be uploaded by the user). Lastly, you can identify the conditions that triggered the event by looking at the associated event snapshot. A snapshot is a group of OEM interface parameters linked to an event. To take a snapshot, you simply specify the time period of the event and the parameters involved. Real-Time Monitoring Application The Real-Time Monitoring application is a powerful tool for preventative maintenance (PM) and troubleshooting. With this application, you can display OEM interface parameters in chart form, in real time for a specified truck, excavator, or auxiliary equipment unit. You can select desired parameters from any OEM interface (KOMTRAX Plus, Statex, VIMS, PLM, etc.) onboard the equipment. You can also display a dashboard of key parameters in real time. This combination gives you a fast and comprehensive look at the current state of your equipment. In Standard and Enterprise editions, the screen also displays DISPATCH information, including equipment ID, group, model, and fleet; operator name; loaded or empty; reason for down event (if applicable); next expected action; estimated time of next expected action; the time of the last action; and the equipment s exact GPS location. Trend Analysis Application The Trend Analysis tool helps you achieve the maximum availability of your mobile equipment fleet. With this The Event Handling application allows early identification of asset health degradation, so you can minimize component and equipment failure. The Real-Time Monitoring application provides a remote view of equipment vital signs information With the Trending Analysis application, you can automatically capture equipment health data and issue alarms when configured conditions are met. MODULAR MINING SYSTEMS, INC. 3
application, you can define condition-based monitoring scenarios and create events based on these scenarios. By combining parameter readings from OEM interfaces, equipment location information, and maintenance personnel s knowledge, you can estimate the condition of components, engines, or equipment. In addition, Trend Analysis allows you to identify potential or impending component failures, as well as continually store parameters for future analysis. Alarm notifications and vital signs snapshots can be controlled directly from the Event Handling utility. This includes audible alarms, automatic e-mails, event source, system, subsystem, sensor fault detection, potential cause, troubleshooting steps, recommended actions, and additional information settings for OEM Events. Maintenance personnel can also export real-time monitoring, snapshot, or trending data into a CSV file for further analysis. The application is easy to set up and use. You first need to decide which parameters you want to monitor, on which equipment, and under which conditions. For example, you might want to monitor all engine exhaust port temperatures and the blowby pressure on your truck fleet, specifically when the trucks are moving and the blowby pressure exceeds a certain level. Once this condition is true, engine exhaust port temperatures and the blowby pressure will be collected and stored for data analysis in chart view or exported to CSV format. Also, you can create trend predictions and then take action. For example, you create events, and/or add behaviors such as increasing the sample time for the parameter collections. the application are typically maintenance specialists, supervisors, and/or technicians. The Equipment Activities board appears as a default screen in the Time Tracking application. This handy reference board graphically shows all equipment that is currently down and the reasons for down events such as scheduled down or unscheduled down. MineCare Time Tracking Application: the Equipment Activities board. The Activity Details screen provides known information for the equipment and activity. Once the repair has been assigned to a technician, the work order number can be entered in the screen. As more information about the repair becomes known, the user fills out the fields accordingly. When repairs are complete, the equipment operator or technician changes the equipment to a nonmaintenance status (Ready, Standby, Delay, etc.) or to another down event if a different repair is necessary. The system then removes the equipment s down status maintenance activity from the Equipment Activities board. There are three types of trend predictions: 1. The Violation type: allows you to set acceptable upper and lower limits to parameter readings. 2. The Increase type: allows you to set a maximum amount of increase for parameter readings. 3. The Predictive type: allows you to create an early warning for parameter readings that may go beyond an acceptable range if present data trends continue. Time Tracking Application The Time Tracking application provides comprehensive handling of down equipment events. It requires only simple data entry and can be easily adopted into your mine s current maintenance practices. Main users of MineCare Time Tracking Application: the Activity Details screen 4 MODULAR MINING SYSTEMS, INC.
FAQs About MineCare What are Trends, and how are they used? Does MineCare require 24-hour monitoring? What equipment does MineCare work with? Does the system inform equipment operators about certain conditions What training and services are available for MineCare? Who in the mining industry is using MineCare? Is there documented success with the system? Trends are condition-based monitoring (CBM) logic based statements that use onboard parameter information and location data to determine: instances where critical sensor data should be collected frequency at which data is collected what User-Defined Event trigger points should be incorporated into the collected data set Although the majority of MineCare customers currently use 24-hour monitoring, the system has the built-in capabilities to automatically collect desired amounts of data, and to notify specific personnel of critical maintenance or operational situations. MineCare Enterprise offers another level of monitoring; it allows multiple sites to be monitored from a single Enterprise system. Sites that may not be able to monitor independently on a 24- hour basis can be consolidated and monitored remotely. Modular has worked with multiple equipment manufacturers resulting in over 100 different interfaces. ModularReady interfaces include Original Equipment Manufacturers (OEMs) such as Komatsu, Caterpillar, Liebherr, and Hitachi. Also included are Tire Manufacturers such as Michelin, Bridgestone, and Goodyear, and third-party technologies such as VSI Oil Advantage, PressurePro, and TireSmart. Modular has an entire Product Development team dedicated to interfaces in order to provide the most comprehensive line of interfaces available. Through MineCare Standard and Enterprise s integration with the DISPATCH system, you can create automatic notifications and messages to the equipment operators through the DISPATCH FastFeedback module. Real-time alerts to the operator can be triggered by OEM events. For example, if a haul truck operator is overusing the brakes on a decline, the system will send a notification to engage the retarder. Modular has qualified trainers available to perform onsite classroom instruction and on-the-job training. Also, the Modular Value Added Services group is available to provide consulting on event management and change management, in order to improve acceptance of the new technology and maximize return on investment. Currently, the MineCare system is being used by over 20 different mining companies around the world, operating at over 50 mines. There have been several documented success stories on the MineCare system, including remote engine diagnostics, failure avoidance, and proven return on investment. Case studies on MineCare are available at www.modularmining.com. MODULAR MINING SYSTEMS, INC. 5
Global and Local Presence Modular s round-the-clock Global Support network provides specialized skills and knowledge alongside regional and global offices to resolve support issues. Support personnel have in-depth access to and experience with our core product technology, and they are constantly looking for ways to provide improved structural services to Modular customers. Tiered Support Modular has established a customer-centric, three-tiered support process that allows the creation of support tickets and new functionality requests. Using our Customer Center and a Global Ticket Response system, issues are categorized by support region, product, type of defect, and resolution priority. Issues are then diagnosed and resolved using the three-tiered process as follows: 1st Tier. Regional support groups serve as the 1st tier of support, and are capable to resolve the majority of technical issues. These groups utilise internal technical support documentation, troubleshooting guides, and online knowledge management systems. Modular also has its online TeamModular Support Forum electronic response network, where our engineers and the customer can interact on issues. 2nd Tier. In the event that regional support cannot fully resolve an issue, it is escalated to the Global Support team. Global Support is responsible for determining whether the issue justifies a new feature request, or if it is a configuration or training problem. The team then works with the 1st tier and mine operational personnel to resolve issues with configuration changes, training, and improving familiarity with the system. 3rd Tier. If Global Support concludes that an issue does justify a new product feature, the item is escalated to the 3rd Tier of support, Product Development (PD). PD collaborates with Marketing to evaluate the issue and decide whether it requires an immediate patch or can be resolved through a future release of the product. Once the course of action is determined, PD works to implement the new functionality through a maintenance release. Modular Mining Systems, Inc. 3289 E. Hemisphere Loop Tucson, AZ 85706-5028 U.S.A. Phone: (520) 746-9127 Fax: (520) 889-5790 www.modularmining.com 2011 Modular Mining Systems, Inc. PF-MRTRUCK-US-11 The contents of these materials are protected by federal and international intellectual property laws. No portion of these materials may be reprinted, republished, modified, reproduced, sold or distributed in any form without the express written consent of Modular Mining Systems, Inc. Modular, IntelliMine, DISPATCH, MineCare, ProVision, ShiftBoss, RoadMap, MasterLink, PowerView, and ModularReady are trademarks and/or registered trademarks and the sole and exclusive property of Modular Mining Systems, Inc. These materials may contain third-party copyright and/or trademark materials, the use of which has not always been specifically authorized by the intellectual property owner. All copyrights and/or trademarks contained in these materials are the sole and exclusive property of their respective owners. These materials, including third-party information, are provided for information purposes only. Actual specifications may vary from those documented in these materials. Consult your local Modular office for further details. 6 MODULAR MINING SYSTEMS, INC.