Juan Arevalo's GET Projects

Overseeing Replacement of Competitor's Lip with Our Company's Lip and Providing Technical Support

Situation: As part of our company's strategic initiative to deliver exceptional technical support and ensure adherence to quality standards, I was assigned to oversee the replacement of a competitor's lip on a hydraulic shovel's bucket with a new lip from our company. The customer requested this replacement following successful sales efforts. The installation was to be carried out at a welding shop that provides services to the mine. My role, as part of the Technical Support Group (TSG), was to provide on-site technical support to ensure that the installation met our company's quality standards and the customer's expectations.

Task: Facilitate the replacement process by training the welding team, defining the work plan, and supervising critical tasks at the welding shop. Ensure that all procedures complied with our company's quality standards and met the customer's expectations for safety and performance.

Action:

• Developed a detailed installation process diagram and a timeline of tasks, emphasizing critical quality checkpoints.
• Provided comprehensive training to the welding shop's team on our company's welding procedures, including preheating, interpass temperatures, filler material selection, and adherence to acceptance criteria.
• Collaborated with the welding shop's supervisors to define the work plan, outlining critical tasks, resource allocation, safety measures, and quality control steps specific to our company's standards.
• Supervised the cutting and removal of the competitor's lip from the bucket, ensuring the preservation of the lateral walls and floor, and adherence to safety protocols.
• Oversaw the cleaning and bevel preparation of the floor, side walls, and lip area, including sandblasting and inspection using penetrant liquids to ensure surfaces met our quality standards.
• Ensured precise alignment of the new lip with the bucket by verifying measurements for depth, parallelism, and inclination, utilizing our company's specifications.
• Guided the welding team in securing the new lip to the bucket using approved methods and materials, maintaining alignment and structural integrity throughout the process.
• Monitored the welding process closely to ensure strict adherence to our company's procedures, including the correct application of root welds and the use of appropriate filler materials to minimize residual stresses.
• Conducted thorough inspections, including non-destructive testing (NDT) with penetrant liquids, to verify weld quality and detect any defects or discontinuities.
• Implemented stress mitigation techniques, such as staggered welding sequences and temper bead applications, in line with our company's best practices to reduce the risk of cracking and enhance fatigue resistance.
• Ensured all work was performed in compliance with safety protocols and quality standards established by our company and expected by the customer.
• Maintained clear communication with the customer to provide updates on progress and address any concerns promptly.

Results:

• Successfully oversaw the replacement of the competitor's lip with our company's new lip on the hydraulic shovel's bucket at the welding shop.
• Enhanced the welding team's skills and knowledge through targeted training, resulting in high-quality workmanship that met our company's standards.
• Ensured the installation process was completed efficiently and safely, minimizing equipment downtime once the bucket was returned to the mine.
• Met all quality assurance criteria, satisfying the customer's expectations and reinforcing their confidence in our company's products and technical support.
• Strengthened the strategic partnership between our company, the welding shop, and the customer, demonstrating our commitment to excellence and customer satisfaction.

Methods Applied:

• DMAIC Methodology (Six Sigma):
  • Define: The project involved replacing a competitor's lip with our company's lip on a hydraulic shovel's bucket. The goal was to ensure the installation met our quality standards and customer expectations while enhancing the welding team's capabilities.
  • Measure:
    • Assessed the welding team's current skill levels and familiarity with our company's procedures.
    • Evaluated the condition of the bucket and the existing lip to determine the scope of work required.
    • Identified critical dimensions and alignment specifications to ensure proper installation.
  • Analyze:
    • Identified potential challenges in the installation process, such as alignment issues and welding quality concerns.
    • Determined gaps in the welding team's knowledge of our procedures that could impact quality.
  • Improve:
    • Provided comprehensive training to address knowledge gaps and improve welding techniques.
    • Implemented a detailed work plan emphasizing critical quality checkpoints and safety measures.
    • Supervised the installation process closely to ensure adherence to procedures and standards.
  • Control:
    • Conducted thorough inspections, including NDT, to verify weld quality and structural integrity.
    • Established documentation of the installation process for future reference and continuous improvement.
    • Maintained ongoing communication with the welding team and the customer to monitor satisfaction and address any post-installation concerns.
• Project Management:
  • Developed a detailed installation process diagram and task timeline, ensuring all critical checkpoints were identified and addressed.
  • Collaborated with supervisors to define the work plan, resource allocation, and safety measures.
  • Managed the project to ensure completion within the expected timeframe while maintaining quality and safety standards.
• Training and Development:
  • Provided comprehensive training to the welding team on our company's welding procedures and quality standards.
  • Enhanced the team's skills in areas such as preheating, interpass temperature control, filler material selection, and adherence to acceptance criteria.
• Quality Assurance and Control:
  • Ensured all procedures complied with our company's quality standards and the customer's expectations.
  • Conducted thorough inspections, including NDT with penetrant liquids, to verify weld quality and detect any defects.
  • Monitored the welding process to ensure strict adherence to procedures, minimizing residual stresses and preventing defects.
• Lean Principles:
  • Optimized the installation process to reduce downtime and enhance efficiency.
  • Eliminated waste by ensuring precise alignment and reducing rework through careful planning and supervision.
• Communication and Collaboration:
  • Maintained clear communication with the customer, providing updates and addressing concerns promptly.
  • Collaborated effectively with the welding shop's supervisors and team to ensure alignment on procedures and standards.
• Risk Management and Safety Compliance:
  • Ensured all work was performed in compliance with safety protocols, minimizing risks to personnel and equipment.
  • Implemented stress mitigation techniques to reduce the risk of cracking and enhance fatigue resistance.
• Continuous Improvement (Kaizen):
  • Applied best practices and company standards to enhance the quality of the installation.
  • Provided feedback and recommendations for future installations to further improve processes.

Developing a Remote GET Monitoring Solution During Pandemic Constraints

Situation: A mining operation with a fleet of 10 cable shovels faced significant challenges in monitoring Ground Engaging Tools (GET) due to strict safety regulations that limited on-site access. Traditionally, inspecting each machine was time-consuming and inefficient, allowing for only zero to three inspections per day. This made it difficult to predict wear and schedule maintenance without disrupting productivity. Initial attempts to gather data remotely included taking photos of GET using zoom cameras from various distances, but these methods were insufficient. With the onset of the COVID-19 pandemic, on-site access was further restricted, exacerbating the inability to monitor GET wear and plan maintenance effectively.

Task: Develop an efficient, effective, and safe method to remotely monitor GET wear and predict maintenance needs during the pandemic, adding value to the customer without requiring on-site presence.

Action:

• Decided to implement a mobile application for operators to use during pre-operational checks, minimizing interactions between operators and mechanics.
• Convinced the managing director of the project's viability, securing approval with a budget limit of $5,000.
• Contracted an external development company to create a pilot version of the mobile application within one month.
• Communicated with the customer to adopt the pilot application for a trial period, focusing on monitoring critical GET components such as specific point positions and identifying worn or damaged tools.
• Enhanced the application during the trial period based on feedback, leading to a final version after three months.
• Developed an Excel model using linear regression to predict the lifespan of GET points.
• Implemented a method to accurately determine the length of GET points from photos within an acceptable error range of 0.25 inches.

Results:

• The mobile application was successfully adopted by the customer, providing real-time information on GET wear for all eleven cable shovels at least twice daily.
• Eliminated the need for direct interaction between operators and mechanics regarding GET issues, enhancing safety during the pandemic.
• Optimized resource utilization by enabling remote monitoring when mechanics could not be present on-site.
• Achieved accurate prediction of GET change intervals, with an error margin of only 0.25 inches on the length of points.
• The application received a customer award for Digital Transformation in 2020.
• Completed the project within the budget, not exceeding the allocated $5,000.
• The success of the application in controlling GET wear on ten cable shovels helped convince the customer to switch an additional shovel to our products, increasing the total to eleven shovels by the end of 2020.

Methods Applied:

• DMAIC Methodology (Six Sigma):
  • Define: The inability to effectively monitor GET wear remotely during the pandemic was impacting maintenance scheduling and productivity. The objective was to develop a safe, efficient remote monitoring solution within a $5,000 budget.
  • Measure: Assessed current monitoring methods, including limited on-site inspections and ineffective remote data collection, quantifying the number of inspections and the inefficiencies involved.
  • Analyze: Identified root causes such as inadequate remote monitoring tools, restricted site access, and the need to minimize interactions due to safety concerns.
  • Improve:
    • Developed a mobile application for operators to use during pre-operational checks.
    • Contracted an external developer to create a pilot version swiftly.
    • Enhanced the application based on trial feedback, resulting in a final version within three months.
  • Control:
    • Implemented the application company-wide, ensuring ongoing use and effectiveness.
    • Monitored GET wear predictions, maintaining an error margin of only 0.25 inches.
• Lean Principles:
  • Eliminated waste by reducing time and resources spent on inefficient inspections.
  • Streamlined the GET monitoring process with a digital solution providing real-time data.
• Agile Methodology:
  • Employed iterative development by launching a pilot, gathering user feedback, and refining the application accordingly.
  • Adapted quickly to changing requirements and constraints imposed by the pandemic.
• Innovation and Problem-Solving:
  • Developed an innovative mobile application to overcome remote monitoring challenges.
  • Implemented a method to accurately measure GET point lengths from photos within an acceptable error range.
• Project Management:
  • Secured project approval and managed it within the budget and time constraints.
  • Coordinated with external developers and internal stakeholders to deliver the application successfully.
• Data-Driven Decision Making:
  • Developed an Excel model using linear regression to predict GET point lifespan based on collected data.
  • Utilized accurate measurements to inform maintenance scheduling and resource allocation.
• Customer Relationship Management (CRM):
  • Engaged closely with the customer to ensure the solution met their needs and added value.
  • Enhanced customer trust by providing a timely and effective solution during a challenging period.
• Continuous Improvement (Kaizen):
  • Improved the application based on user feedback during the trial period.
  • Committed to ongoing enhancements to maximize the application's effectiveness.
• Digital Transformation:
  • Facilitated the customer's shift towards digital solutions, modernizing their GET monitoring process.
  • The application's success was recognized with a customer award for Digital Transformation in 2020.

Resolving Frequent Point Breakages on Cable Shovels to Maintain Supplier Relationship

Situation: A mining customer was experiencing frequent breakages of their cable shovels' GET points, leading to falling points during operation. This issue was significantly affecting the availability and productivity of their fleet of cable shovels. As a result, the customer was considering changing their GET supplier for all 11 of their cable shovels due to these negative impacts.

Task: Develop a solution to address the broken GET points that would meet the customer's expectations and retain the company's position as the GET supplier for the mine.

Action:

• Provided dedicated on-site technical support to work exclusively on resolving the issue.
• Despite similar issues occurring in the past at another mine, approached this case without assumptions by collecting fresh data and symptoms specific to this situation.
• Conducted boneyard analyses and fractographic examinations of the broken points to understand the failure mechanisms.
• Identified variables associated with the breakage events, including point position, digging conditions, machine type, wear condition of adapter noses, measurement data at the time of failure, manufacturing lot numbers, and operator practices.
• Performed problem analysis using Pareto charts and Ishikawa (fishbone) diagrams to detect patterns and repeated factors contributing to the failures.
• Conducted finite element analysis focusing on dynamic movements to detect stress effects of impacts on the existing point design and compared it with new design proposals from the engineering team.
• Prepared and delivered a technical presentation outlining the proposed solution to the customer's management and maintenance teams, aiming to convince them of the effectiveness of the new design.

Results:

• Successfully convinced the customer to adopt the new updated GET point design, which addressed the negative effects and resolved the breakage issues.
• Identified patterns where breakage events were more likely to occur, particularly at slope limits with poor blasting and double-bank formations of 30 meters in height, providing valuable insights for operational adjustments.
• Retained the company's position as the GET supplier for the mine's cable shovels, maintaining the business relationship and customer trust.

Methods Applied:

• Root Cause Analysis (RCA):
  • Conducted boneyard analyses and fractographic examinations to identify the underlying failure mechanisms of the broken GET points.
  • Investigated variables such as point position, digging conditions, machine type, wear conditions, and operator practices to determine contributing factors.
• DMAIC Methodology (Six Sigma):
  • Define: The customer was experiencing frequent GET point breakages, threatening the supplier relationship; the goal was to develop a solution that met customer expectations.
  • Measure: Collected fresh data on breakage events, including measurements at the time of failure and manufacturing lot numbers.
  • Analyze: Used Pareto charts and Ishikawa diagrams to detect patterns and repeated factors contributing to failures.
  • Improve:
    • Collaborated with the engineering team to help with feedback to design a new GET point that addressed identified issues.
    • Conducted finite element analysis to test the new design's performance under dynamic stress conditions.
  • Control:
    • Presented the proposed solution to the customer's management and maintenance teams to gain approval.
    • Monitored the performance of the new GET points to ensure the issue was resolved.
• Data-Driven Decision Making:
  • Based solutions on quantitative data collected from the field, ensuring that recommendations were supported by evidence.
  • Used statistical tools like Pareto charts to prioritize factors contributing to failures.
• Finite Element Analysis (FEA):
  • Performed FEA focusing on dynamic movements to detect stress effects on the existing and proposed point designs.
  • Validated the new design's ability to withstand operational stresses, reducing the likelihood of future breakages.
• Customer Relationship Management (CRM):
  • Provided dedicated on-site support to demonstrate commitment to resolving the customer's issues.
  • Communicated effectively with the customer throughout the process, maintaining transparency and trust.
• Continuous Improvement (Kaizen):
  • Approached the problem with fresh data and open-mindedness, despite previous similar issues elsewhere.
  • Implemented design improvements based on analysis, contributing to the ongoing enhancement of product quality.

Assessing Hinge Neck Breakages and Ensuring Proper Installation on Hydraulic Face Shovels

Situation: A mining operation was experiencing frequent breakages of hinge necks on the front of their hydraulic face shovels. The customer was concerned that improper system greasing and the presence of unblasted material—due to local community issues—were contributing factors. They requested assistance in measuring the front components to identify any misalignments or wear that could be causing the failures.

Task: Conduct measurements of the shovel's front components to assess their condition, determine the root cause of the hinge neck breakages, and provide guidance to prevent future occurrences. Additionally, evaluate the repair processes at the welding facility responsible for overhauling these components.

Action:

• Visited the mining site to perform measurements on the shovel's front components, focusing on the bushing faces due to safety constraints.
• Despite challenges such as heavy winds affecting laser measurements and surfaces contaminated with grease, obtained critical measurements (e.g., dimensions A, B, C, D, and ILW) to assess potential misalignments.
• Collaborated with the customer to discuss findings and address their concerns, ensuring they were satisfied with the reported measurements.
• Visited the welding shop responsible for overhauling the shovel components to observe the repair processes and discuss the frequent hinge neck breakages.
• Examined previously repaired hinge necks, noting that some had been rebuilt and operated for significant hours without issues.
• Assessed the welding procedures, materials used (such as H4 tubular wire and solid wire E110-18), and heat control measures to ensure quality rebuilds.
• Identified the need for proper installation instructions for specific components to prevent future failures.
• Agreed to prioritize technical support presence during the upcoming installation of the front and backboard on the hydraulic face shovel.

Results:

• Provided the customer with accurate measurements and a thorough assessment of the shovel's front components, addressing their immediate concerns.
• Confirmed that the welding shop maintained high-quality repair standards, contributing to improved hinge neck integrity.
• Established a plan to offer on-site technical support during future installations, aiming to prevent recurrence of hinge neck breakages.
• Enhanced the customer's confidence in the support provided, fostering a stronger professional relationship.

Methods Applied:

• Root Cause Analysis (RCA):
  • Investigated the frequent hinge neck breakages by measuring front components to identify misalignments or wear.
  • Analyzed potential contributing factors such as improper system greasing and unblasted material presence.
• DMAIC Methodology (Six Sigma):
  • Define: Frequent hinge neck breakages on hydraulic face shovels were causing operational issues; the goal was to determine root causes and prevent future occurrences.
  • Measure: Collected critical measurements of front components despite environmental challenges to assess potential misalignments or wear.
  • Analyze: Evaluated measurements and repair processes to identify factors contributing to hinge neck failures.
  • Improve:
    • Collaborated with the customer to address concerns and provide accurate assessments.
    • Identified the need for proper installation instructions and technical support during future installations.
  • Control:
    • Planned for on-site technical support to ensure proper installation and prevent recurrence of issues.
    • Monitored repair processes at the welding facility to maintain high-quality standards.
• Quality Assurance and Control:
  • Assessed welding procedures and materials used to ensure quality rebuilds of hinge necks.
  • Confirmed that the welding shop adhered to high-quality repair standards.
• Lean Principles:
  • Optimized the assessment process by overcoming environmental challenges to obtain necessary measurements efficiently.
  • Reduced potential downtime by proactively planning technical support during installations.
• Collaboration and Communication:
  • Worked closely with the customer to address their concerns and ensure satisfaction with the findings.
  • Facilitated communication between the customer and welding facility to align on repair standards and practices.
• Project Management:
  • Coordinated site visits and assessments despite safety constraints and environmental challenges.
  • Developed a plan to provide technical support during future installations to prevent issues.
• Continuous Improvement (Kaizen):
  • Identified the need for proper installation instructions to enhance future equipment reliability.
  • Committed to ongoing support and improvement by agreeing to prioritize technical presence during installations.
• Data-Driven Decision Making:
  • Used precise measurements and assessments to inform recommendations and action plans.
  • Based decisions on quantitative data despite measurement challenges.

Investigating Shroud Failures and Enhancing GET Performance on Hydraulic Front Shovels

Situation: A mining operation was experiencing issues with their hydraulic front shovels due to the falling of center shrouds. These failures were causing operational inefficiencies, safety concerns, and premature wear of Ground Engaging Tools (GET). Additionally, the customer sought to improve the overall performance and lifespan of their GET systems across their fleet.

Task: Investigate the root cause of the center shroud failures, evaluate the performance of the GET on the hydraulic front shovels, and provide effective solutions to enhance equipment reliability and productivity.

Action:

• Conducted an on-site visit to inspect the equipment and assess the failure mechanisms of the center shrouds.
• Identified that a specific component at the bottom of the shroud assembly had a radius causing negative effects, leading to failures.
• Developed a solution involving modifications to the component, increasing the tolerance by 3 mm on the back base to prevent future failures.
• Evaluated the shroud rebuilding practices and found that tolerances were at maximum levels, recommending adjustments to decrease the gap and improve fitment.
• Noted that the new design of the lifting eye on the side of the shroud was causing installation difficulties; proposed modifications to facilitate easier installation.
• Analyzed wear patterns on shrouds in different positions, observing premature wear in specific areas, and recommended targeted measures to address these issues.
• Reviewed the use of wing shrouds and advised that certain protective measures were unnecessary, potentially reducing premature removal and replacement.
• Met with the customer's reliability manager to discuss findings and agreed on implementing the proposed solutions.

Results:

• Provided the customer with a comprehensive understanding of the root causes of the shroud failures.
• Implemented modifications to components and maintenance practices, reducing the likelihood of future shroud falls.
• Improved the installation process for shrouds by addressing design issues, enhancing efficiency and safety.
• Enhanced the performance and lifespan of the GET through targeted recommendations and adjustments.
• Increased customer satisfaction by delivering prompt and effective solutions, strengthening the professional relationship.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified the underlying issues causing the center shroud failures, such as the negative effects of a specific component's radius.
  • Analyzed failure mechanisms through on-site inspections to determine the fundamental causes of operational inefficiencies and safety concerns.
• DMAIC Methodology (Six Sigma):
  • Define: The frequent falling of center shrouds was causing inefficiencies and safety risks; the goal was to investigate and provide effective solutions.
  • Measure: Collected data on shroud failures, wear patterns, and installation difficulties.
  • Analyze: Evaluated component designs, tolerances, and maintenance practices to identify factors contributing to failures.
  • Improve:
    • Modified the problematic component by increasing tolerance by 3 mm to prevent future failures.
    • Adjusted shroud rebuilding practices to decrease gaps and improve fitment.
    • Proposed design modifications to the lifting eye to facilitate easier installation.
    • Recommended targeted measures to address premature wear in specific areas.
  • Control:
    • Established new maintenance practices and guidelines to sustain improvements.
    • Scheduled follow-up meetings with the reliability manager to monitor the effectiveness of implemented solutions.
• Lean Principles:
  • Eliminated waste by reducing downtime caused by shroud failures and inefficient installation processes.
  • Optimized equipment performance by improving GET lifespan and reliability.
  • Streamlined maintenance practices to enhance operational efficiency.
• Data-Driven Decision Making:
  • Used precise measurements and analysis of wear patterns to inform recommendations.
  • Based solutions on quantitative data collected during inspections and evaluations.
• Problem-Solving and Innovation:
  • Developed innovative modifications to components and designs to address specific failure causes.
  • Proposed practical solutions to installation difficulties, enhancing safety and efficiency.
• Collaboration and Communication:
  • Worked closely with the customer's reliability manager and maintenance team to understand concerns and implement solutions.
  • Facilitated open dialogue to ensure alignment on proposed changes and their benefits.
• Continuous Improvement (Kaizen):
  • Identified opportunities to enhance GET performance and maintenance practices continuously.
  • Encouraged ongoing assessment and refinement of equipment components and procedures.
• Quality Assurance and Control:
  • Ensured that modifications met operational standards and improved equipment reliability.
  • Monitored the implementation of solutions to maintain high-quality performance levels.

Repairing and Refurbishing a Shovel's Dipper Door

Situation: A mining customer required repair and refurbishment of a dipper door on a 15-cubic-yard capacity shovel. The door had damaged components that needed replacement and reassembly to restore functionality. The project involved enabling a safe work environment, removing damaged parts, fixing structural elements, welding new components, and ensuring the door met operational standards.

Task: Provide technical support and oversee the repair process of the shovel's dipper door. Ensure all procedures were performed according to quality standards and customer expectations while maintaining safety and efficiency.

Action:

• Coordinated with the customer to prepare the worksite, ensuring all safety and quality standards were met.
• Contracted a welder and a company to supply a welding assistant, along with necessary tools and equipment.
• Inspected incoming replacement parts to confirm they arrived in good condition.
• Noted a missing template required for bending a new component; created a custom template based on measurements from the original door using an arc meter.
• Bent the new upper recess plate to match the required angles (41° left and 45° right) to ensure proper fit.
• Installed a tie bar to maintain alignment during the bending and welding process.
• Cleaned all surfaces of oxide and paint before cutting and welding; marked centerlines for precise alignment.
• Monitored and controlled temperatures during cutting and welding (preheated to 300°F and maintained interpass temperatures up to 500°F) to ensure weld quality.
• Used E7018 electrodes heated to 250°F as filler material for welding.
• Removed the damaged upper recess and upper tunnel plates according to engineering procedures.
• Trimmed the door beam tunnel by approximately 2 inches to fit the profile of the new upper tunnel plate.
• Assembled and welded the new upper tunnel plate and upper recess plate, ensuring proper alignment and fit.
• Performed penetrant testing (PT) inspections to verify weld integrity and quality finish.
• Applied a protective paint coating to the repaired door.
• Left the worksite clean and orderly, returning it to the customer's standards.
• Facilitated a final review with the customer, who measured and inspected the work, expressing satisfaction with the results.

Results:

• Successfully repaired and refurbished the dipper door, restoring it to full operational condition.
• Met all quality and safety standards, ensuring the customer's satisfaction and confidence in the repairs.
• Completed the project efficiently without the need for follow-up actions.
• Strengthened the professional relationship with the customer by demonstrating technical expertise and a commitment to excellence.

Methods Applied:

• DMAIC Methodology (Six Sigma):
  • Define: The dipper door had damaged components needing repair and refurbishment; the goal was to restore functionality while meeting quality and safety standards.
  • Measure:
    • Assessed the extent of damage to the dipper door and identified all components requiring replacement or repair.
    • Inspected incoming replacement parts to ensure they met specifications.
  • Analyze:
    • Identified potential challenges, such as the missing template for bending the new component, which could affect alignment and fit.
    • Evaluated welding procedures and temperature controls needed to ensure weld quality.
  • Improve:
    • Created a custom template based on accurate measurements to replace the missing one.
    • Implemented precise welding techniques, including temperature control and proper filler material selection.
    • Ensured proper alignment and fit of new components through careful assembly and installation of tie bars.
  • Control:
    • Performed penetrant testing (PT) inspections to verify weld integrity and quality finish.
    • Maintained documentation of procedures and measurements for future reference.
    • Facilitated a final review with the customer to confirm satisfaction and adherence to standards.
• Project Management:
  • Coordinated resources, including contracting a welder and welding assistant, to ensure the project had the necessary personnel and equipment.
  • Developed a work plan that aligned with quality standards and customer expectations.
  • Managed timelines effectively to complete the project efficiently without delays.
• Lean Principles:
  • Optimized the repair process by eliminating waste and inefficiencies, such as creating a custom template when the original was missing.
  • Streamlined workflows by ensuring all surfaces were prepared properly before welding, reducing the likelihood of rework.
• Quality Assurance and Control:
  • Conducted inspections of incoming replacement parts to ensure they were in good condition.
  • Monitored and controlled temperatures during cutting and welding to ensure weld quality and prevent defects.
  • Performed penetrant testing (PT) inspections to verify weld integrity and quality finish.
• Root Cause Analysis (RCA):
  • Identified that the missing template could cause delays and inaccuracies; addressed this by creating a custom template based on accurate measurements.
• Training and Development:
  • Ensured that all team members were informed of the proper procedures and safety standards to maintain high-quality workmanship.
• Communication and Collaboration:
  • Maintained open communication with the customer throughout the project to align on expectations and provide updates.
  • Collaborated with the welding team to ensure precise alignment and adherence to technical specifications.
• Safety Management:
  • Prepared the worksite to meet all safety standards, ensuring a safe working environment for all personnel involved.
  • Monitored welding temperatures to prevent safety hazards associated with overheating.
• Continuous Improvement (Kaizen):
  • Improvised by creating a custom template, which can be used for future projects to improve efficiency.
  • Left the worksite clean and orderly, setting a standard for future projects and enhancing overall efficiency.

Accelerated Conversion to Our GET System Through Modified Stabilizer Installation

Situation: A customer was dissatisfied with the performance of a competitor's Ground Engaging Tools (GET) system, which failed to meet expectations. The customer expressed interest in transitioning to our GET system for four cable shovels. However, a full conversion process, including on-site welding, would take years due to time and operational constraints. To address this challenge, a temporary solution was required to facilitate an immediate conversion without impacting shovel availability or productivity.

Task: Develop and oversee the implementation of a modified stabilizer design that could enable the swift conversion from the competitor's GET system to ours without requiring on-site welding. Ensure the solution met operational standards and minimized downtime for the customer.

Action:

• Collaborated with the engineering team to design a stabilizer compatible with our GET system, allowing installation without welding.
• Performed stress and performance analyses on the modified stabilizer to validate its effectiveness and durability.
• Created detailed installation instructions, emphasizing proper torque application and a re-torque procedure within 24 hours post-installation to maintain structural integrity.
• Provided training to welding shop staff to ensure they could execute the installation process efficiently and in compliance with quality standards.
• Supervised the installation process at a controlled welding shop environment, ensuring precise alignment and adherence to technical specifications.
• Documented the process to create a scalable approach for similar future conversions.

Results:

• Enabled immediate conversion of four cable shovels to our GET system, bypassing the lengthy process of on-site welding.
• Reduced installation time and operational disruptions, allowing the customer to maintain shovel availability and productivity.
• Improved the customer's perception of our GET system by delivering a tailored, efficient, and effective solution.
• Increased the likelihood of long-term adoption of our GET system by demonstrating superior technical support and adaptability.
• Reinforced our company's reputation for providing innovative solutions to complex operational challenges.

Methods Applied:

• DMAIC Methodology (Six Sigma):
  • Define: The customer needed an immediate conversion from a competitor's GET system to ours without lengthy on-site welding. The objective was to develop a quick, effective solution that minimized downtime and met operational standards.
  • Measure:
    • Assessed the time and operational constraints that made traditional conversion methods impractical.
    • Evaluated the customer's equipment specifications to determine compatibility requirements for the modified stabilizer.
  • Analyze:
    • Identified that the primary barriers were the time-intensive welding process and the need to maintain shovel availability.
    • Analyzed the feasibility of designing a non-welded stabilizer that could be installed quickly and safely.
  • Improve:
    • Collaborated with engineering to design a modified stabilizer compatible with our GET system.
    • Performed stress and performance analyses to validate the new design.
    • Developed detailed installation instructions and provided training to ensure proper execution.
  • Control:
    • Supervised the installation process to ensure adherence to specifications and quality standards.
    • Documented the process for scalability and future conversions.
    • Established re-torque procedures and ongoing monitoring to maintain structural integrity.
• Lean Principles:
  • Eliminated waste by reducing installation time and avoiding prolonged downtime associated with on-site welding.
  • Optimized processes by developing a modified stabilizer that allowed for quick installation without compromising quality.
• Innovative Problem-Solving:
  • Developed a creative solution to enable immediate conversion, demonstrating adaptability and responsiveness to customer needs.
  • Collaborated with engineering to design a non-welding installation method, overcoming operational constraints.
• Project Management:
  • Coordinated cross-functional teams, including engineering and welding shop staff, to ensure successful implementation.
  • Managed timelines effectively to meet the customer's urgent need for conversion without impacting productivity.
• Quality Assurance and Control:
  • Performed stress and performance analyses to validate the modified stabilizer's effectiveness and durability.
  • Emphasized proper installation procedures, including torque specifications and re-torque protocols, to maintain structural integrity.
• Training and Development:
  • Provided training to welding shop staff on the new installation process to ensure compliance with quality standards.
  • Enhanced the team's capabilities to execute similar conversions efficiently in the future.
• Continuous Improvement (Kaizen):
  • Documented the installation process to create a scalable approach for future conversions.
  • Identified opportunities to refine and improve the solution based on feedback and performance outcomes.
• Customer Relationship Management (CRM):
  • Strengthened the relationship with the customer by providing a tailored solution that addressed their immediate needs.
  • Demonstrated commitment to customer success by minimizing disruptions and enhancing operational efficiency.
• Risk Management:
  • Mitigated risks associated with prolonged conversion timelines by implementing a quick and effective solution.
  • Ensured the modified stabilizer met safety and performance standards to prevent potential operational issues.

Analyzing and Resolving Lip Shroud Breakages on Front-End Loaders

Situation: A mining operation was experiencing a high number of broken lip shrouds on their front-end loaders (FELs), with 21 incidents reported over a four-month period. The majority of breakages occurred on a specific model of FEL, particularly on one unit that had eight breakages. These failures were causing significant operational challenges and downtime.

Task: Conduct a thorough analysis to determine the root causes of the lip shroud breakages and develop effective solutions to prevent future occurrences.

Action:

• Visited the mining site to inspect the affected FELs, focusing on the unit with the highest number of breakages.
• Attempted to remove the lip shrouds for inspection but encountered difficulties due to hinge pin obstructions and the accumulation of fine materials (argillic) between the shroud and lip.
• Observed an excess of 1 mm on the boss within the hinge pin gap, contributing to removal challenges.
• Noted the presence of fine material trapped between the shroud and lip, which can increase stress and wear.
• Utilized gauges to measure wear on the front lip but found that incorrect reference points were being used, leading to inaccurate assessments.
• Corrected the measurement method and determined that there was a 4 mm wear on both the left and right sides of the front lip.
• Identified that wear in the high-stress areas of the front lip was a primary factor contributing to the shroud breakages.
• Recognized the need to check wear on the bed lip of the hinge pin, which could also be a contributing factor.
• Recommended the design and manufacture of a new specialized gauge to accurately measure wear on the lip and hinge pin areas.

Results:

• Successfully identified the root causes of the lip shroud breakages, allowing for targeted corrective actions.
• Developed a plan to create a new gauge to improve the accuracy of wear measurements, facilitating better maintenance practices.
• Scheduled follow-up actions to address the lip wear issues using the new gauge, aiming to reduce future breakages and enhance equipment reliability.
• Met the objectives of the analysis, providing the mining operation with actionable insights and solutions to improve their FEL performance.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified multiple factors contributing to lip shroud breakages, including wear in high-stress areas, accumulation of fine materials, and hinge pin obstructions.
  • Conducted thorough inspections to understand the underlying issues affecting the FELs.
• DMAIC Methodology (Six Sigma):
  • Define: Frequent lip shroud breakages on FELs were causing operational challenges; the goal was to determine root causes and develop solutions.
  • Measure: Collected data on the number of breakages, wear measurements, and identified incorrect measurement practices.
  • Analyze: Evaluated the wear patterns, obstruction issues, and measurement inaccuracies to identify primary factors causing breakages.
  • Improve:
    • Corrected measurement methods to obtain accurate wear assessments.
    • Recommended designing a specialized gauge for precise measurement of wear on the lip and hinge pin areas.
  • Control:
    • Planned follow-up actions to use the new gauge for ongoing wear monitoring.
    • Established better maintenance practices to prevent future breakages.
• Lean Principles:
  • Eliminated waste by addressing the root causes of breakages, reducing downtime and maintenance costs.
  • Improved operational efficiency by enhancing equipment reliability through targeted corrective actions.
• Continuous Improvement (Kaizen):
  • Identified the need for a specialized gauge to improve measurement accuracy, contributing to better maintenance practices.
  • Implemented corrective actions based on insights gained, fostering an environment of ongoing improvement.
• Data-Driven Decision Making:
  • Utilized accurate measurements and inspection data to inform the analysis and solutions.
  • Recognized the impact of incorrect measurement practices and corrected them to ensure reliable data.
• Collaboration and Communication:
  • Worked closely with the mining operation's maintenance team to gather information and observations.
  • Communicated findings and recommendations effectively, ensuring alignment on next steps.
• Problem-Solving and Innovation:
  • Developed the concept of a new specialized gauge to address measurement challenges.
  • Innovated solutions to overcome obstacles such as hinge pin obstructions and fine material accumulation.

Repairing Cracks on a Mining Shovel Dipper Door During Preventive Maintenance

Situation: A large mining shovel was experiencing structural issues due to numerous cracks found on its dipper (bucket) door. An initial inspection identified 21 cracks, but during preventive maintenance (PM), an additional 9 cracks were discovered, bringing the total to 30. These cracks posed a significant risk to the shovel's operational integrity and safety, requiring immediate attention to prevent downtime and potential accidents.

Task: Provide technical support and supervision to repair the identified cracks on the dipper door during the scheduled PM. Ensure that the repairs were conducted according to proper welding procedures, addressing the most severe cracks within the limited maintenance window.

Action:

• Collaborated with the welding supervisor to develop specific welding procedures tailored to the crack repairs.
• Prioritized the repair of the most severe cracks during the PM period.
• Utilized appropriate welding materials (Dual Shield II 80-Ni1H4 wire) to ensure high-quality and durable welds.
• Maintained optimal welding conditions by monitoring and keeping the work temperature above 150°C.
• Reinforced critical joints by installing A514 steel plates over the welding joints of the cross-brace and flange-brace.
• Added wear plates with a hardness of 500 HB on the bottom of the dipper door at the customer's request to enhance durability.
• Coordinated with the customer's team to ensure preliminary tasks, such as cleaning with air-arc gouging, were completed promptly to allow repair work to begin.
• Developed a plan for future PMs to address remaining cracks, install gusset plates on hoist lugs, replace non-original rubber bumpers with original ones, and reinforce weld bevels using specialized tools.

Results:

• Successfully repaired 12 of the most severe cracks during the PM, significantly improving the structural integrity of the dipper door.
• Reduced the risk of operational failure and enhanced the safety of the shovel during excavation activities.
• Established a collaborative workflow with the customer's maintenance team, leading to more efficient repair processes.
• Prepared for subsequent maintenance activities to completely resolve the cracking issues and implement long-term preventative measures.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified that the structural issues were due to numerous cracks in the dipper door, posing risks to operational integrity and safety.
  • Determined that immediate attention was required to prevent downtime and potential accidents.
• DMAIC Methodology (Six Sigma):
  • Define: The dipper door had 30 cracks needing repair during PM; the goal was to repair the most severe cracks within the limited maintenance window using proper welding procedures.
  • Measure: Assessed the severity and locations of all 30 cracks, prioritizing them based on risk and impact.
  • Analyze: Evaluated current welding practices and materials to determine the best approach for effective and durable repairs.
  • Improve:
    • Developed specific welding procedures tailored to the crack repairs.
    • Utilized high-quality welding materials and maintained optimal welding conditions.
    • Reinforced critical joints and added wear plates to enhance durability.
    • Coordinated with the customer's team to ensure efficient workflow and prompt completion of preliminary tasks.
  • Control:
    • Established a plan for future PMs to address remaining cracks and implement preventative measures.
    • Maintained collaboration with the maintenance team for ongoing monitoring and timely repairs.
• Lean Principles:
  • Optimized the repair process to minimize downtime by prioritizing the most severe cracks during the limited PM window.
  • Eliminated waste by coordinating tasks effectively and ensuring prompt completion of preliminary work.
  • Improved workflow efficiency through collaboration and clear communication with the maintenance team.
• Quality Assurance and Control:
  • Maintained optimal welding conditions and used appropriate materials to ensure high-quality, durable repairs.
  • Reinforced critical areas to enhance structural integrity and prevent future failures.
  • Implemented plans for future maintenance to address remaining issues and maintain equipment reliability.
• Project Management:
  • Developed a strategic plan to address the most critical repairs within the limited maintenance timeframe.
  • Coordinated resources and tasks effectively to maximize efficiency.
  • Monitored progress and adjusted plans as needed to ensure successful completion of repairs.
• Collaboration and Communication:
  • Worked closely with the customer's maintenance team to establish a collaborative workflow.
  • Ensured clear communication regarding priorities, procedures, and timelines.
  • Aligned efforts to enhance efficiency and effectiveness of the repair process.
• Continuous Improvement (Kaizen):
  • Developed a plan for future PMs to address remaining cracks and implement preventative measures.
  • Identified opportunities to enhance durability, such as adding wear plates and reinforcing weld bevels.
  • Committed to ongoing improvements in maintenance practices to ensure long-term equipment reliability.
• Safety Management:
  • Prioritized repairs that posed the highest risk to operational safety.
  • Implemented proper welding procedures to prevent accidents and equipment failure.
  • Enhanced safety during excavation activities by reinforcing structural integrity.

Supervising Assembly of 115 Cubic Yard Dragline Bucket Within Projected Timeline

Situation: A customer purchased a 115 cubic yard bucket for a dragline, manufactured by our company. The bucket arrived at the mine in four parts to be assembled on-site. According to the manufacturer's estimate, the assembly was expected to take 20 days.

Task: Provide support and supervision for the assembly of the bucket, ensuring adherence to the manufacturer's assembly procedures and completion within the projected 20-day timeframe.

Action:

• Developed a comprehensive work plan with the team, including the customer, based on assembly procedures, drawings, and the expected timeline.
• Confirmed the availability of necessary resources such as cranes, equipment, and welders.
• Defined tasks for day and night shifts in accordance with the customer's safety regulations.
• Assigned a technical support representative for each shift to oversee the assembly process.

Results:

• Successfully completed the assembly by strictly following the drawings and procedures.
• Delivered the project on time, meeting the expectations of both the customer and the engineering team.

Methods Applied:

• Project Management:
  • Developed a comprehensive work plan aligning with assembly procedures, drawings, and timeline.
  • Coordinated resources, including equipment and personnel, ensuring availability when needed.
  • Managed schedules for day and night shifts, adhering to safety regulations.
• Agile Methodology:
  • Applied iterative planning and daily briefings to adapt to changes and address challenges promptly during the assembly process.
  • Fostered collaboration and open communication among team members and stakeholders to ensure transparency and rapid problem-solving.
• Lean Principles:
  • Optimized assembly processes to eliminate waste and increase efficiency.
  • Allocated tasks effectively to reduce downtime and bottlenecks.
• Communication and Collaboration:
  • Worked closely with the customer and team members to align on objectives and expectations.
  • Assigned technical support representatives to maintain clear communication and oversight during each shift.
• Standardization and Quality Assurance:
  • Strictly adhered to manufacturer's assembly procedures and drawings to ensure quality and consistency.
  • Implemented standard work practices to maintain high-quality outcomes.
• Risk Management and Safety Compliance:
  • Defined tasks in accordance with the customer's safety regulations to mitigate risks.
  • Ensured all activities were conducted safely, preventing accidents and delays.
• Time Management:
  • Scheduled tasks effectively to meet the projected 20-day timeframe.
  • Monitored progress regularly to stay on track and make adjustments as necessary.

Repairing Cracks on a Dragline Bucket and Ensuring Welding Quality

Situation: A customer reported issues with a large dragline bucket supplied by our company. While the bucket demonstrated an 8% increase in productivity compared to others, the customer was concerned about cracks in the original welding joints, affecting the bucket's performance and durability.

Task: Provide on-site assistance to repair the cracks under warranty, ensure that welding repairs met industry standards, and restore the customer's confidence in the product's quality.

Action:

• Traveled to the customer's site to assist and supervise the repair of the bucket's cracks.
• Delivered a presentation to the customer's welders and supervisors, explaining the crack repair procedures and welding techniques according to our company's standards.
• Collaborated with the welding team to excavate the cracks following precise specifications:
  • Identified cracks in the left-hand side connection between the cheek plate and cheek plate extension.
  • Excavated cracks measuring approximately 11.5 inches long, with excavation dimensions of 16 inches in length, 3.5 inches in depth, and 2.75 inches in width.
  • Installed tie bars to stabilize the structure during excavation when reaching depths of 3 inches or more.
• Preheated the excavation area to 250°F to prevent thermal stress.
• Performed liquid penetrant testing (PT) on excavated areas to detect additional cracks, ensuring inspections were done below 104°F (40°C).
• Applied initial weld layers using E7018 electrodes, followed by additional welding with E71T-1 filler material.
• Implemented temper bead techniques with a welding preheat of 350°F to reduce residual stresses and prevent cracking.
• Protected weld areas from rain to maintain integrity during and after the welding process.
• Ground the welds to remove stress raisers and smooth sharp edges, enhancing structural integrity.
• Completed ultrasonic testing (UT) according to industry standards (AWS D1.1), ensuring repaired areas met acceptance criteria for cyclically loaded connections.
• Identified and repaired an additional crack in the sand plug area, following similar procedures for excavation, welding, and inspection.
• Conducted PT inspections on other critical areas of the bucket to ensure no additional cracks were present.

Results:

• Successfully repaired all identified cracks on the dragline bucket, restoring its structural integrity.
• Ensured all welding repairs met industry standards and passed non-destructive testing inspections.
• Enhanced the customer's confidence in the quality of our products and repair procedures.
• Received positive feedback regarding the bucket's improved performance and the professionalism of the repair process.
• Completed the project without the need for follow-up repairs, achieving all objectives during the visit.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified that cracks in original welding joints were affecting the bucket's performance and durability.
  • Determined that proper repair procedures and welding techniques were necessary to resolve the issues.
• DMAIC Methodology (Six Sigma):
  • Define: Cracks in the bucket's welding joints needed repair; the goal was to ensure repairs met industry standards and restored performance.
  • Measure: Assessed the size and extent of cracks through inspections and non-destructive testing (NDT) methods.
  • Analyze: Evaluated existing welding techniques and identified areas for improvement.
  • Improve:
    • Implemented precise repair procedures following industry standards.
    • Provided training to welders on proper welding techniques.
    • Applied advanced welding methods, such as temper bead techniques, to enhance repair quality.
  • Control:
    • Conducted NDT inspections (PT and UT) to ensure repairs met acceptance criteria.
    • Ensured repaired areas passed industry-standard tests and were free from defects.
• Quality Assurance and Control:
  • Adhered to industry standards (AWS D1.1) for welding repairs and testing.
  • Performed rigorous NDT inspections to verify the integrity of repairs.
  • Implemented proper preheating and welding techniques to prevent future cracking.
• Training and Development:
  • Delivered presentations to welders and supervisors on crack repair procedures and welding techniques.
  • Enhanced the welding team's skills to maintain high-quality repair standards.
• Lean Principles:
  • Improved efficiency by implementing effective repair procedures, reducing the likelihood of future failures.
  • Eliminated waste associated with rework and downtime due to equipment failures.
• Communication and Collaboration:
  • Worked closely with the customer's welding team to ensure alignment on repair procedures.
  • Maintained open communication with the customer to manage expectations and provide updates.
• Continuous Improvement (Kaizen):
  • Applied lessons learned to enhance repair procedures and welding techniques.
  • Encouraged ongoing skill development among the welding team.

Resolving Pin Misalignment and Enhancing Welding Procedures on Dredging Equipment

Situation: A customer was unable to install a pin through the rear and front bushings of a dredge bucket due to misalignment issues. Additionally, there were concerns about improper welding procedures affecting the installation of wear components and the repair of cracks on their dredging equipment. The welding quality was impacting equipment performance, and the customer's welders required training to improve their techniques.

Task: Provide on-site technical support to resolve the pin misalignment issue on the dredge bucket. Develop specific welding procedures for installing corner wear shoes, repairing cracks, and rebuilding worn nose adapters. Train the customer's welders to enhance welding quality and prevent future equipment failures.

Action:

• Inspected the dredge bucket to identify the cause of the pin misalignment.
• Discovered excessive weld bead buildup on the beam and rock shield plate, causing misalignment of the bores.
• Carefully removed the excess weld material from the beam and rock shield plate to allow for proper alignment.
• Installed brace bars to maintain structural integrity during the welding process.
• Re-welded the components following precise instructions to ensure correct alignment.
• Verified alignment by measuring the bores on both sides, confirming they were parallel within acceptable tolerances (a difference of 0.97 mm).
• Developed specific welding procedures for installing corner wear shoes and repairing cracks on the dredging equipment.
• Provided training to the customer's welders on proper welding techniques for rebuilding worn nose adapters, addressing issues with component wear and failure.
• Advised on repair procedures for another dredge bucket to enhance overall equipment reliability.

Results:

• Successfully resolved the pin misalignment issue, allowing smooth installation of the pin through the bushings.
• Improved welding quality on the customer's dredging equipment by implementing specific procedures and providing targeted training.
• Enhanced the customer's confidence in our technical support and solutions, strengthening our professional relationship.
• Completed all objectives during the visit without the need for follow-up, ensuring the equipment was operational and reliable.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified that excessive weld bead buildup on the beam and rock shield plate was causing misalignment of the bores, preventing pin installation.
  • Recognized that improper welding procedures were leading to equipment performance issues and failures.
• DMAIC Methodology (Six Sigma):
  • Define: The dredge bucket had pin misalignment and welding quality issues affecting performance; the goal was to resolve misalignment and enhance welding practices.
  • Measure: Assessed the extent of misalignment by measuring the bores and evaluated the current welding procedures and skill levels of the customer's welders.
  • Analyze: Determined that excessive weld bead buildup was the root cause of misalignment and that gaps in welding techniques were causing equipment failures.
  • Improve:
    • Removed excess weld material to correct the misalignment.
    • Re-welded components following precise instructions to ensure proper alignment.
    • Developed specific welding procedures for various repairs.
    • Provided targeted training to the customer's welders to enhance their skills and prevent future issues.
  • Control:
    • Verified alignment within acceptable tolerances after repairs.
    • Ensured adherence to new welding procedures through training and documentation.
    • Monitored equipment performance to confirm the effectiveness of the solutions implemented.
• Lean Principles:
  • Reduced downtime by promptly addressing the misalignment issue, improving operational efficiency.
  • Eliminated waste associated with repeated equipment failures and rework due to poor welding quality.
  • Streamlined processes by standardizing welding procedures and training, enhancing overall productivity.
• Training and Development:
  • Enhanced the customer's welders' skills through on-site training in proper welding techniques and procedures.
  • Empowered the welding team to maintain higher quality standards, reducing future equipment issues.
• Quality Assurance and Control:
  • Implemented precise measurement and verification techniques to ensure correct alignment and structural integrity.
  • Developed and documented specific welding procedures to maintain consistent quality across repairs.
• Collaboration and Communication:
  • Worked closely with the customer to understand their challenges and expectations.
  • Maintained open communication throughout the project, providing updates and involving them in the solution process.
  • Advised on repair procedures for additional equipment, demonstrating commitment to their overall operational success.
• Continuous Improvement (Kaizen):
  • Identified opportunities to enhance welding practices and equipment reliability.
  • Implemented improvements that not only resolved current issues but also prevented future problems.
  • Encouraged a culture of ongoing development and adherence to best practices within the customer's team.
• Problem-Solving and Innovation:
  • Utilized innovative approaches to remove excess weld material without compromising structural integrity.
  • Applied precise alignment techniques and installed brace bars to maintain equipment stability during repairs.

Facilitating Lip Installation and Providing Training on Shovel Bucket

Situation: A customer required assistance with the installation of a new lip on a mining shovel bucket. During the initial installation, there were alignment issues between the lip and the wing base of the bucket. Additionally, the customer requested a welding and GET (Ground Engaging Tools) clinic for mine supervisors and welding service providers. The installation process was interrupted due to a welder strike, necessitating a return visit to complete the work and inspect the final installation.

Task: Ensure the proper installation of the new lip on the shovel bucket by resolving alignment issues and overseeing the welding process. Provide training to supervisors and welding personnel on proper welding techniques and the benefits of new GET products to enhance future installations and maintenance practices.

Action:

• Attempted the installation of the new lip, identifying misalignment between the lip and the wing base.
• Worked on assembling the lip with the bucket, supervising the welding process to ensure proper procedures were followed.
• Applied external support plates on the wing base lip and utilized temper bead welding techniques to enhance structural integrity.
• Provided detailed instructions and steps to the remaining team to continue the work during the welder strike.
• Returned to the site after the strike to inspect the completed installation and assess the quality of the work.
• Took videos and photos of the shovel in operation to document performance and installation quality.
• Recommended improvements, such as enhancing wear protection on the wing base and reducing gaps to a minimum of 0.25 inches.
• Conducted a welding and GET clinic for mine supervisors and welding service providers, sharing best practices and product benefits.

Results:

• Successfully resolved the alignment issues and facilitated the proper installation of the new lip on the shovel bucket.
• Improved the quality of the welding and installation process through direct supervision and training.
• Provided valuable recommendations that enhanced the durability and performance of the equipment.
• Strengthened the relationship with the customer by addressing their needs and providing technical support.
• Completed the project successfully without the need for further follow-up.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified that misalignment between the lip and wing base was causing installation issues.
  • Analyzed installation procedures to determine factors contributing to alignment problems.
  • Recognized that lack of proper guidance and techniques was leading to structural integrity concerns.
• DMAIC Methodology (Six Sigma):
  • Define: Installation of the new lip was hindered by alignment issues, and there was a need for training; the goal was to resolve these issues and improve future practices.
  • Measure: Assessed the degree of misalignment and evaluated current welding practices and knowledge levels among personnel.
  • Analyze: Identified gaps in welding techniques and procedural adherence contributing to installation problems.
  • Improve:
    • Supervised the welding process, ensuring proper procedures were followed.
    • Applied external support plates and temper bead welding to enhance structural integrity.
    • Provided training through a welding and GET clinic, enhancing skills and knowledge.
  • Control:
    • Established guidelines and best practices for future installations.
    • Recommended design improvements to reduce gaps and enhance wear protection.
    • Ensured that the team could continue work effectively during interruptions (e.g., welder strike) through detailed instructions.
• Lean Principles:
  • Minimized downtime by promptly addressing alignment issues and providing solutions.
  • Reduced waste by improving welding techniques, decreasing the likelihood of rework or equipment failure.
  • Streamlined the installation process through effective supervision and application of best practices.
• Training and Development:
  • Conducted a welding and GET clinic for supervisors and service providers, enhancing their skills and knowledge.
  • Improved future installation and maintenance practices by educating personnel on proper techniques and product benefits.
  • Empowered the team to perform high-quality work independently, reducing reliance on external support.
• Project Management:
  • Coordinated the installation project despite interruptions due to the welder strike.
  • Provided clear instructions to the team to maintain progress during unforeseen delays.
  • Managed timelines effectively to ensure project completion without further follow-up needed.
• Communication and Collaboration:
  • Maintained open communication with the customer to understand their needs and provide updates.
  • Collaborated with the welding team to resolve technical issues and improve practices.
  • Documented the installation process through videos and photos to share insights and ensure transparency.
• Quality Assurance and Control:
  • Supervised the welding process to ensure adherence to proper procedures and standards.
  • Inspected the final installation to assess quality and identify any areas needing improvement.
  • Implemented recommendations to enhance equipment durability and performance.
• Continuous Improvement (Kaizen):
  • Provided feedback and recommendations to enhance future installations.
  • Encouraged ongoing skill development through training sessions and sharing best practices.
  • Adapted to challenges, such as the welder strike, by adjusting plans and ensuring continuity of work.

Resolving Installation Issues with Updated Shrouds on Cable Shovels

Situation: The installation of updated shrouds on high-capacity cable shovels was challenging due to poor fitting, causing the shrouds to fall off shortly after installation, even when practically new. These issues led to increased downtime for the cable shovels, negatively affecting productivity.

Task: Find a quick solution to help the customer achieve the expected performance from the new updated shrouds.

Action:

• Visited the mine to observe symptoms and identify the underlying problem.
• Analyzed the boneyard and conducted fractographic examinations of the broken shrouds.
• Consulted with the engineering team to determine any design differences between the new updated shrouds and the previous version.
• Created an internal bi-dimensional gauge based on drawings provided by the engineering team.
• Measured the internal opening of the shrouds using the gauge.
• Modified the lip according to the gauge measurements and adjusted the position of the boss to meet the new specifications.

Results:

• Discovered that the internal opening of the new shrouds was approximately 3 mm narrower than the previous version.
• Successfully modified the lip and adjusted the boss position to accommodate the updated shrouds.
• After fixing all 16 base positions, no further incidents of shroud breakage occurred.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified that the shrouds were falling off due to poor fitting caused by design differences in the new shrouds.
  • Conducted fractographic examinations to understand the failure mechanisms of the broken shrouds.
  • Discovered that the internal opening of the new shrouds was narrower by approximately 3 mm compared to the previous version.
• DMAIC Methodology (Six Sigma):
  • Define: The problem was the frequent falling off of new shrouds due to poor fitting, leading to downtime; the goal was to quickly find a solution to restore expected performance.
  • Measure: Measured the internal openings of both new and old shrouds and assessed the fitting issues on the lips.
  • Analyze: Compared design specifications to identify discrepancies causing the fitting problem.
  • Improve:
    • Modified the lip and adjusted the boss position based on precise gauge measurements.
    • Developed and utilized an internal bi-dimensional gauge for accurate modifications.
  • Control: After modifying all base positions, monitored the performance to ensure no further shroud breakages occurred.
• Lean Principles:
  • Reduced downtime by swiftly identifying and addressing the root cause of the fitting issue.
  • Eliminated waste associated with repeated shroud replacements and repairs.
  • Improved efficiency in the installation process by ensuring proper fit and reducing the need for rework.
• Collaboration and Communication:
  • Worked closely with the engineering team to obtain accurate design drawings and understand changes.
  • Maintained open communication with the customer to provide updates and manage expectations.
• Problem-Solving and Innovation:
  • Developed a custom internal bi-dimensional gauge to precisely measure and rectify the fitting issue.
  • Implemented practical modifications to the existing equipment to accommodate the updated shrouds effectively.

Modification of Hydraulic Shovel Lip

Situation: A customer requested the modification of a hydraulic shovel lip to accommodate new adapters. The existing lip, made from 12T alloy, required precise adjustments to ensure compatibility. This project was conducted in collaboration with the welding team at a site managed by the customer, with logistical support provided by the Panama Canal Authority.

Task: Develop and implement a precise cutting and grinding process for the lip to meet specifications for maximum tolerance and alignment. Ensure that the process adhered to quality standards and prepared the lip for seamless adapter installation.

Action:

• Designed and created male and female templates based on engineering drawings to guide the cutting process.
• Traced equidistant centerlines on the lip to maintain alignment throughout the cutting procedure.
• Performed arc-air cutting of the designated areas after preheating the lip to 120°C to ensure proper material behavior during cutting.
• Used grinding tools to remove slag to a depth of 3mm and eliminate sharp edges, achieving a smooth finish.
• Conducted measurements with a gauge to verify uniformity and ensure the maximum tolerance of 0.25 inches for the adapter fit.
• Completed the modifications on two lips, ensuring consistency and precision throughout the process.

Results:

• Achieved a precise fit between the modified lip and the new adapters, meeting the customer's requirements.
• Ensured the structural integrity and performance of the lip by adhering to strict quality control procedures, including preheating and proper material finishing.
• Enhanced customer trust and satisfaction through professional execution and attention to detail.
• Developed a repeatable cutting procedure for future similar modifications, improving efficiency and reliability for the customer.

Methods Applied:

• Lean Principles:
  • Optimized the cutting and grinding process to eliminate waste and improve efficiency, ensuring timely completion.
  • Streamlined workflow by designing templates and standardizing procedures, reducing variability and errors.
• Quality Assurance and Control:
  • Adhered to strict quality control measures, including preheating to 120°C and precise measurements to maintain tolerances.
  • Conducted thorough inspections at each stage to ensure structural integrity and proper alignment.
• DMAIC Methodology (Six Sigma):
  • Define: Needed to modify the hydraulic shovel lip precisely to accommodate new adapters, ensuring compatibility and performance.
  • Measure: Collected specifications for maximum tolerances and alignment requirements; assessed current lip dimensions and material properties.
  • Analyze: Identified potential challenges in cutting and grinding processes that could affect quality and alignment.
  • Improve:
    • Developed templates and standardized cutting procedures to enhance precision.
    • Implemented preheating and controlled grinding techniques to ensure material stability and finish quality.
  • Control: Established a repeatable procedure with consistent results, allowing for future modifications with the same level of quality.
• Standardization and Process Documentation:
  • Created detailed templates and process documentation to ensure consistency across multiple modifications.
  • Provided clear guidelines and standards for the welding team to follow, reducing the risk of errors.
• Collaboration and Communication:
  • Worked closely with the customer's welding team and coordinated with the Panama Canal Authority for logistical support.
  • Maintained open communication to align on project goals, timelines, and quality expectations.
• Continuous Improvement (Kaizen):
  • Refined the cutting and grinding process based on initial outcomes to improve efficiency and precision.
  • Developed a repeatable procedure that could be used for future modifications, enhancing reliability and customer satisfaction.
• Project Management:
  • Planned and executed the project within the agreed timeframe, coordinating resources and schedules effectively.
  • Ensured all team members understood their roles and responsibilities, leading to a successful project outcome.

Repair and Rebuild of XDPM Bucket for Dredging Division

Situation: A critical bucket utilized by the dredging division of a major waterway authority required warranty repairs and extensive rebuilding due to cracks, misalignments, and wear. The initial welding quality during manufacturing was subpar, leading to structural failures that affected performance and durability. Additionally, local welding crews lacked the expertise needed for this specialized task.

Task: Lead the repair and rebuilding process to ensure the bucket's functionality met operational standards. This involved creating a clear process flow, providing training to local welders, and overseeing all critical repair stages to ensure quality and durability.

Action:

• Conducted a thorough inspection of the bucket to identify defects, including cracks in weld joints, wear on critical zones, and misalignments.
• Developed a detailed process flow diagram to guide the repair and rebuilding process.
• Provided daily updates and continuous communication with technical engineering teams to ensure alignment with quality standards.
• Verified the welding skills of local contractors and supervised the repair process to guarantee adherence to specified procedures.
• Used advanced non-destructive testing (NDT) methods, such as Magnetic Particle Inspection (MPI), to identify and confirm crack removal before welding repairs.
• Preheated components to 350°F and performed repairs using E7018 electrodes for high-quality welding.
• Installed brace bars to maintain structural alignment during repairs and removed them once welding was completed.
• Reinforced critical wear zones with protective plates, enhancing the bucket's durability and extending its lifespan.

Results:

• Successfully repaired cracks and reinforced structural components, restoring the bucket to operational standards.
• Improved weld quality ensured the bucket's long-term performance and durability.
• Enhanced wear resistance with the addition of protective plates in critical zones.
• Trained local welders in advanced repair techniques, leaving a skilled workforce capable of maintaining similar equipment in the future.
• Delivered the project within the expected timeline, meeting customer expectations and reinforcing trust in technical support services.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified that subpar welding quality during initial manufacturing was the root cause of structural failures.
  • Determined that misalignments and cracks were resulting from inadequate welding procedures and lack of skilled personnel.
• DMAIC Methodology (Six Sigma):
  • Define: The bucket required extensive repairs due to structural failures affecting performance; the goal was to restore it to operational standards efficiently.
  • Measure: Assessed the extent of defects through thorough inspections and NDT methods, quantifying the areas needing repair.
  • Analyze: Evaluated the welding techniques used during manufacturing and identified gaps in local welders' expertise.
  • Improve:
    • Developed a detailed repair process flow diagram.
    • Provided targeted training to local welders on advanced repair techniques and proper welding procedures.
    • Implemented preheating and used high-quality electrodes to enhance weld integrity.
  • Control: Supervised the repair process, conducted continuous quality checks, and ensured adherence to the new procedures to prevent recurrence of issues.
• Lean Principles:
  • Eliminated waste by streamlining the repair process and reducing rework through proper planning and skilled execution.
  • Optimized resource utilization by training local welders, reducing dependence on external specialists.
  • Improved workflow efficiency with a clear process flow and effective communication among teams.
• Training and Development:
  • Enhanced the skills of local welders through hands-on training in advanced welding and repair techniques.
  • Built a competent local workforce capable of maintaining and repairing equipment in the future, contributing to continuous improvement.
• Quality Assurance and Control:
  • Implemented rigorous quality control measures, including NDT methods like MPI, to ensure defects were properly addressed.
  • Used high-quality welding materials and adhered to best practices to enhance the durability of repairs.
• Project Management:
  • Developed and managed a detailed project plan to ensure timely completion of repairs.
  • Maintained continuous communication with technical teams and the customer to align expectations and provide updates.

Installing Wing Base on Cable Shovel Following Manufacturer's Welding Procedures

Situation: A requirement emerged to install a new wing base on a high-capacity cable shovel to enhance its operational efficiency. Adherence to the manufacturer's specific welding procedures was crucial to ensure safety and meet performance standards.

Task: Perform the installation of the wing base according to the manufacturer's welding procedures, aligning with customer expectations regarding quality and completion time.

Action:

• Obtained the manufacturer's welding procedure documentation from the global technical support and engineering teams.
• Developed a detailed work plan with the supervisor, ensuring it complied with the welding procedures and met the customer's time expectations.
• Conducted training sessions for the supervisor and welding crew on the specific welding procedures to be followed.

Results:

• Successfully completed the wing base installation in accordance with the manufacturer's welding procedures and the customer's expectations.
• Achieved a proper fit of the wing shrouds upon installation, enhancing the shovel's performance.

Methods Applied:

• DMAIC Methodology (Lean Six Sigma):
  • Define: The objective was to install a new wing base to enhance operational efficiency, requiring strict adherence to the manufacturer's welding procedures and alignment with customer expectations for quality and timing.
  • Measure: Assessed current installation processes, collected the manufacturer's welding procedures, and documented customer requirements for quality and completion time.
  • Analyze: Identified gaps between existing practices and the manufacturer's procedures, evaluating potential risks such as safety hazards and performance issues due to non-compliance.
  • Improve:
    • Developed a comprehensive work plan that incorporated the manufacturer's welding procedures and met the customer's time expectations.
    • Conducted targeted training sessions for the supervisor and welding crew to ensure proper understanding and execution of the specific welding techniques required.
  • Control: Implemented monitoring during the installation to ensure adherence to the procedures, and established quality checks post-installation to verify the proper fit and performance of the wing shrouds.
• Lean Principles:
  • Optimized the installation process to eliminate waste, reduce delays, and improve overall efficiency.
  • Streamlined communication and coordination between teams to ensure a smooth workflow and timely completion.
• Compliance and Quality Assurance:
  • Ensured strict adherence to the manufacturer's welding procedures to maintain safety standards and achieve the desired performance quality.
  • Performed rigorous quality checks to confirm the proper fit and functionality of the installed components.
• Training and Development:
  • Enhanced team competency by providing specialized training on the manufacturer's welding procedures.
  • Promoted a culture of continuous learning and adherence to best practices among the welding crew.
• Project Management:
  • Effectively planned and coordinated the installation project to meet deadlines and exceed customer expectations.
  • Managed resources and timelines to ensure efficient use of personnel and materials, minimizing disruptions.

Securing GET Supply for New High-Capacity Cable Shovels Amidst Competitor Challenge

Situation: After our company won a previous competition against a major competitor, a customer intended to equip their three new high-capacity cable shovels (each with a 73 cubic yard capacity, significantly larger than their existing 56 cubic yard shovels) with our Ground Engaging Tools (GET). However, by the time the decision was made, two of the shovels were already in transit fitted with a new competitor's GET system. When the first shovel arrived, the customer decided to conduct a six-month comparative trial between the competitor's GET on that shovel and our GET, to determine which system to adopt for all shovels. These new shovels were critical to the mine's productivity.

Task: At the customer's request, our technical support team was to monitor the performance of the competitor's GET system on the first shovel to ensure that its productivity was not compromised.

Action:

• Inspected the competitor's GET system with a focus on lock-out reliability and overall performance.
• Monitored key performance indicators such as GET change times, optimal replacement intervals to prevent unplanned downtime, GET lifespan, and safety during GET changes.
• Ensured maintenance crews followed the competitor's recommended procedures for GET installation and removal.

Results:

• After three months of the trial, numerous issues were observed with the competitor's GET, including falling points, loss of penetration efficiency, difficulty removing adapters, and falling shrouds.
• The customer decided to replace the competitor's GET with our company's GET system on the first shovel.
• The second shovel, upon arrival at the mine, was immediately fitted with our GET system before commencing operations.
• Secured our company's position as the GET supplier for all new high-capacity shovels, enhancing the mine's productivity and reinforcing customer trust.

Methods Applied:

• Competitive Analysis and Strategic Positioning:
  • Monitored the competitor's GET performance to gather data on potential weaknesses and issues.
  • Used insights from the trial to demonstrate the superior reliability and efficiency of our GET system.
  • Positioned our company as a proactive and supportive partner by assisting the customer even when using a competitor's product.
• Data-Driven Decision Making:
  • Collected and analyzed key performance indicators (KPIs) such as GET change times, lifespan, and safety incidents.
  • Provided the customer with factual, quantitative evidence of the performance differences between the two GET systems.
• Customer Relationship Management (CRM):
  • Maintained open communication with the customer, building trust through transparency and reliability.
  • Demonstrated commitment to the customer's success by ensuring their productivity was not compromised during the trial.
  • Enhanced customer loyalty by promptly addressing issues and providing superior solutions.
• Problem-Solving and Adaptability:
  • Quickly identified issues with the competitor's GET system and prepared our team to implement our solutions seamlessly.
  • Adapted to the unexpected challenge by turning the trial into an opportunity to showcase our strengths.
• Lean Principles:
  • Improved operational efficiency for the customer by reducing downtime associated with GET issues.
  • Eliminated waste caused by frequent maintenance and replacements of the competitor's GET components.
• Continuous Improvement (Kaizen):
  • Used feedback from the trial to further enhance our GET system's performance and reliability.
  • Continually assessed and improved our support services to meet and exceed customer expectations.

Reducing Downtime in Cable Shovels through Six Sigma Collaboration

Situation: Four cable shovels were experiencing 30 hours of downtime per month due to Ground Engaging Tools (GET) events, negatively impacting mine productivity by 40%.

Task: Collaborate on a Six Sigma project to reduce downtime caused by GET events by 13 hours on Bucyrus 495BII cable shovels.

Action:

• Analyzed response times involved in each task during unplanned and planned maintenance.
• Identified the most significant events contributing to downtime using the 80/20 principle.
• Enhanced installation and removal procedures for GET.
• Standardized tools and equipment for each crew.
• Developed information cards detailing GET and necessary tools for each cable shovel.
• Established satellite warehouses near digging areas stocked with critical GET components.
• Conducted training on correct methods for installing and removing GET, focusing on efficiency, effectiveness, and safety.
• Provided general training for the entire operations team on GET issues and detection methods.

Results:

• Reduced downtime from 30 hours to 5 hours per month.
• Increased trust in the service provided, facilitating the introduction of new products.
• Achieved Six Sigma certification for the service team as collaborators.

Methods Applied:

• Six Sigma DMAIC Methodology:
  • Define: Downtime due to GET events was causing significant productivity losses; the goal was to reduce downtime by 13 hours per month.
  • Measure: Collected data on response times, maintenance activities, and downtime occurrences for each shovel.
  • Analyze: Used the 80/20 principle to identify that a small number of issues were causing the majority of downtime, focusing on the most impactful areas.
  • Improve:
    • Enhanced GET installation and removal procedures to reduce time and errors.
    • Standardized tools and equipment across crews to ensure consistency and efficiency.
    • Developed information cards with detailed instructions and tool lists for quick reference.
    • Established satellite warehouses to decrease retrieval time for critical components.
    • Conducted targeted training sessions to improve skills and adherence to new procedures.
  • Control: Implemented ongoing monitoring of downtime metrics and maintenance practices to sustain improvements and make further adjustments as needed.
• Lean Principles:
  • Eliminated waste by streamlining maintenance processes and reducing unnecessary movement and delays.
  • Optimized resource utilization by standardizing tools and equipment.
  • Improved workflow efficiency, leading to increased productivity.
• Training and Development:
  • Enhanced crew competencies through focused training on efficient and safe GET handling procedures.
  • Improved overall team performance by providing knowledge on GET issues and detection methods.
• 80/20 Principle (Pareto Analysis):
  • Identified that 20% of the issues were causing 80% of the downtime.
  • Prioritized addressing these critical issues to achieve the most significant reduction in downtime.

Enhancing Cable Shovel Productivity through Optimized GET Point Design

Situation: Premature loss of tip penetration due to impact conditions caused by poor blasting was resulting in decreased shovel productivity. This was evidenced by increased truck loading times for the Caterpillar equipment.

Task: Analyze various Ground Engaging Tools (GET) point designs—at least three different options focusing on shape, weight, and length—according to the specific digging conditions of the area, with the goal of increasing cable shovel productivity.

Action:

• Collected operator feedback on the performance of the current GET points.
• Assessed the abrasion levels of the slope based on the lifespan of the current points.
• Discussed three selected GET point options with the geological and operations teams.
• Conducted testing of the new proposed points, measuring truck loading times and point lifespans.

Results:

• Reduced truck loading time by 17 seconds over four passes when using the new points compared to the current points.
• Increased cable shovel productivity by 30%.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified that poor blasting conditions were causing impact issues leading to premature loss of tip penetration.
  • Recognized that this was directly affecting shovel productivity and increasing truck loading times.
• DMAIC Methodology:
  • Define: Shovel productivity was decreasing due to premature wear of GET points under current conditions.
  • Measure: Collected data on truck loading times and GET point lifespans with existing designs.
  • Analyze: Assessed operator feedback and abrasion levels to understand the impact on GET performance.
  • Improve: Tested and implemented optimized GET point designs focusing on shape, weight, and length suitable for the specific digging conditions.
  • Control: Monitored the performance of the new GET points, ensuring sustained productivity improvements.
• Lean Principles:
  • Enhanced efficiency by reducing truck loading times, thereby increasing overall productivity.
  • Eliminated waste associated with frequent GET point replacements due to premature wear.
• Continuous Improvement (Kaizen):
  • Incorporated operator feedback to continuously refine GET point designs.
  • Engaged in iterative testing of different point options to identify the most effective design.
• Data-Driven Decision Making:
  • Relied on quantitative data from testing to select the optimal GET point design.
  • Used performance metrics such as loading times and point lifespan to make informed decisions.

Enhancing Safety and Efficiency in GET Removal with Water Pressure System

Situation: There was a high risk of accidents caused by metal splinters (3mm particles) detaching from the surface of Ground Engaging Tools (GET) during removal under fine material conditions. This risk was due to the use of hammers on GET to remove fines, despite the tools being designed as hammerless. Additionally, removing and installing GET was difficult and time-consuming because of the fine material, significantly affecting cable shovel productivity. There was also a potential risk of GET falling off during excavation due to improper installation practices, such as inadequate cleaning of fines leading to poor fitting and incorrect torque applied to locking mechanisms.

Task: Develop a safer and more efficient method for GET removal and installation using water pressure, focusing on improving safety and reducing the time required for these processes.

Action:

• Updated the safety work procedure (PST file) after experimentation and validation by the operations manager.
• Coordinated the availability of a cistern truck during GET change times.
• Tested various high-pressure nozzles to select the most effective one.

Results:

• Eliminated the use of hammers during GET change work, reducing the risk of metal splinter accidents to zero.
• Reduced removal time from 1 hour to 15 minutes for each adapter or shroud, and from 1 hour to 20 minutes for nine points.
• Simplified the GET removal and installation processes.
• Increased machine availability, leading to higher productivity in areas with fine material.
• Enhanced trust in the service provided.

Methods Applied:

• Root Cause Analysis (RCA):
  • Identified that the use of hammers on hammerless GET was causing metal splinter hazards.
  • Recognized that fine materials were leading to difficult and time-consuming removal and installation, causing productivity losses.
  • Determined that improper cleaning and incorrect torque application were causing GET to fall off during excavation.
• Lean Principles:
  • Eliminated waste by reducing removal time significantly, increasing operational efficiency.
  • Improved safety measures, thereby reducing potential costs associated with workplace accidents.
  • Optimized the GET change process to enhance machine availability and productivity.
• DMAIC Methodology:
  • Define: Safety hazards and inefficiencies in GET removal and installation processes were affecting productivity and posing risks.
  • Measure: Assessed removal times and documented incidents related to metal splinter accidents and GET failures.
  • Analyze: Identified root causes such as hammer use, inadequate cleaning, and improper torque application.
  • Improve: Introduced a water pressure system, updated safety procedures, and coordinated necessary resources like the cistern truck.
  • Control: Validated the new process with management, updated standard operating procedures, and monitored ongoing performance to ensure sustained improvements.
• Continuous Improvement (Kaizen):
  • Conducted experiments with various high-pressure nozzles to select the most effective one, continually refining the process.
  • Updated and standardized work procedures to reflect the improved method, ensuring consistent application across teams.
  • Encouraged feedback from operators to identify further improvement opportunities.
• Safety Management Systems:
  • Enhanced safety protocols by eliminating hazardous practices and introducing safer methods.
  • Provided training on the new procedures to all personnel involved, fostering a culture of safety.
  • Implemented regular safety audits to ensure compliance and address any new risks promptly.

Securing Competitive Advantage in Cable Shovel GET Supply

Situation: A competitive evaluation was underway between our company and a competitor to supply Ground Engaging Tools (GET) for cable shovels. Each company provided GET for two cable shovels operating under similar conditions. The customer planned to assess performance over six months to determine the preferred supplier. During this period, one of our shovels experienced issues with the points, resulting in 32 breakages in one month, causing customer concern and dissatisfaction with our products.

Task: Despite the challenging situation, the objective was to ensure our company was chosen as the preferred supplier over the competitor.

Action:

• Demonstrated exceptional customer service to build trust and showcase our commitment to solving issues promptly.
• Engaged in proactive communication with the customer to understand their concerns and expectations.
• Conducted a thorough analysis of the breakage issues to quickly identify the root cause.
• Developed and implemented a new, shorter point design to eliminate the breakages and improve performance.
• Provided faster and safer GET change procedures to minimize downtime.
• Leveraged our solutions to highlight the overall value we offer beyond just the product.

Results:

• Won the competitive evaluation and was selected as the preferred GET supplier over the competitor.
• Achieved lower cost per tonne and cost per hour compared to the competitor, resulting in savings of $300,000 per year across two shovels.
• Provided faster and safer GET change times than the competitor, reducing operational delays.
• Reduced downtime due to GET issues more effectively than the competitor.
• Enhanced customer trust in our service, facilitating the introduction of new products based on solutions developed in previous projects.

Methods Applied:

• Competitive Strategy and Differentiation:
  • Focused on delivering exceptional service to differentiate ourselves from the competitor, emphasizing our commitment to customer success.
  • Highlighted our ability to rapidly solve critical issues, demonstrating added value beyond the product itself.
• Root Cause Analysis (RCA):
  • Quickly identified the cause of the breakages through vectorial force analysis and fractographic examination.
  • Developed an effective solution—a shorter point design—to resolve the issue swiftly, restoring product reliability.
• Customer Relationship Management (CRM):
  • Built strong relationships with key stakeholders by maintaining transparent and proactive communication.
  • Demonstrated reliability and responsiveness, increasing customer confidence in our ability to meet their needs.
• DMAIC Methodology:
  • Define: Needed to secure the contract by outperforming the competitor and addressing customer concerns.
  • Measure: Tracked breakage incidents and compared performance metrics between us and the competitor.
  • Analyze: Assessed both technical issues and customer service gaps affecting the customer's perception.
  • Improve: Implemented design changes and enhanced service protocols to resolve issues and exceed customer expectations.
  • Control: Monitored ongoing performance to ensure sustained improvement and customer satisfaction.
• Lean Principles:
  • Minimized waste and downtime by improving GET change times and eliminating frequent breakages.
  • Optimized processes to deliver cost savings and operational efficiencies, giving us a competitive edge.

Securing Competitive Advantage in Cable Shovel GET Supply

Situation: A competitive evaluation was underway between our company and a competitor to supply Ground Engaging Tools (GET) for cable shovels. Each company provided GET for two cable shovels operating under similar conditions. The customer planned to assess performance over six months to determine the preferred supplier. During this period, one of our shovels experienced issues with the points system, resulting in several breakages in one month, causing customer concern and dissatisfaction with our products.

Task: Despite the challenging situation, the objective was to ensure our company was chosen as the preferred supplier over the competitor by addressing the breakage issues and demonstrating superior service and value.

Action:

• Demonstrated exceptional service to the customer, emphasizing reliability and responsiveness beyond the product itself.
• Built customer trust by providing timely solutions and open communication regarding the issues faced.
• Analyzed the vectorial distribution of forces due to the length of the GET points, noting that breakage events were more frequent when the point was new and at maximum length.
• Performed fractographic analysis on the broken point surfaces to identify the initiation points of fractures and understand the failure mechanisms.
• Collaborated with the engineering team to address breakage issues by introducing a new, shorter point design to reduce leverage effects and enhance durability.
• Implemented faster and safer GET change procedures to minimize downtime and improve operational efficiency.

Results:

• Our company was selected over the competitor as the preferred GET supplier for the customer's cable shovels.
• Achieved lower cost per tonne and cost per hour compared to the competitor, resulting in savings of $300,000 per year across two shovels.
• Provided faster and safer GET change times than the competitor, reducing operational disruptions.
• Reduced downtime due to GET issues compared to the competitor, enhancing overall productivity.
• Enhanced customer trust in our service, facilitating the introduction of new products based on solutions developed in previous projects.

Methods Applied:

• DMAIC Methodology (Six Sigma):
  • Define: Frequent breakages of the GET points were causing customer dissatisfaction and risking loss of supplier status.
  • Measure:
    • Recorded 32 breakages in one month, indicating a significant reliability issue.
    • Collected data on the conditions under which breakages occurred, including point length and operational parameters.
  • Analyze:
    • Analyzed force distribution due to point length using vectorial analysis to understand the stress factors.
    • Performed fractographic studies to identify fracture initiation sites and failure mechanisms.
    • Determined that the length of the GET points when new contributed to increased leverage and breakages.
  • Improve:
    • Collaborated with engineering to design and introduce a shorter point to reduce leverage and mitigate breakages.
    • Enhanced GET change procedures to be faster and safer, minimizing downtime.
    • Provided exceptional customer service to address concerns promptly and build trust.
  • Control:
    • Monitored the performance of the new point design to ensure reduction in breakages.
    • Maintained strong communication with the customer to ensure satisfaction and address any ongoing issues.
    • Implemented regular reviews and feedback loops to sustain improvements.
• Root Cause Analysis (RCA):
  • Identified that the excessive length of the GET points when new was causing increased leverage, leading to breakages.
  • Determined that breakage events were more frequent at maximum point length, necessitating a design change.
  • Used fractographic analysis to pinpoint fracture initiation sites and understand material behavior under stress.
• Lean Principles:
  • Reduced downtime and waste by promptly addressing the root cause of GET failures.
  • Improved efficiency with faster and safer GET change times compared to the competitor, enhancing operational flow.
  • Optimized resource utilization by reducing the frequency of breakages and replacements.
• Continuous Improvement (Kaizen):
  • Built ongoing customer trust by providing exceptional service and responsiveness to issues.
  • Leveraged insights from previous projects to introduce new products and solutions tailored to customer needs.
  • Encouraged a culture of continuous improvement within the team, focusing on customer satisfaction and product reliability.
• Customer Relationship Management (CRM):
  • Maintained open and transparent communication with the customer throughout the evaluation period.
  • Demonstrated commitment to resolving issues and meeting the customer's needs promptly.
  • Enhanced the customer's perception of our company by exceeding service expectations.
• Data-Driven Decision Making:
  • Based design improvements on quantitative data from breakage incidents and force analyses.
  • Used statistical analysis to compare performance metrics against the competitor.
• Agile Methodology:
  • Responded swiftly to the breakage issue by iterating on the point design in collaboration with engineering.
  • Adapted strategies quickly based on customer feedback and performance data.
• Risk Management:
  • Identified the risk of losing the supplier status and implemented measures to mitigate it through product improvement and customer service.
  • Monitored the implementation of the new point design to ensure it addressed the breakage issues effectively.

Optimizing GET Refurbishment Practices

Situation: The uncontrolled use of Ground Engaging Tools (GET) scrap led to decreased performance and shorter lifespans for refurbished GET. Frequent failures caused unplanned downtime, negatively impacting operational efficiency and productivity in mining operations.

Task: Conduct comprehensive research to evaluate the pros and cons of the current GET refurbishment practices and implement improvements to enhance performance, reliability, and cost-effectiveness.

Action:

• Evaluated existing refurbishment designs to ensure compatibility with new GET designs, maintaining performance standards.
• Determined optimal refurbishment limits for each base or plate to maximize performance while preventing overuse.
• Assessed the quality of scrap materials used in the refurbishment process, implementing strict quality control measures.
• Introduced identification marks on refurbished GET to track the number of refurbishment cycles and monitor performance over time.
• Conducted a boneyard analysis of refurbished GET to gather data on wear patterns, failure modes, and overall performance.
• Standardized refurbishment practices by developing clear guidelines and procedures for the refurbishment process.

Results:

• Defined a maximum of three refurbishment cycles per core, with approval from the customer, ensuring optimal performance and safety.
• Maintained an annual expenditure of $1 million, representing significant cost savings compared to purchasing new GET.
• Enhanced operational efficiency by reducing unplanned downtime caused by GET failures.
• Improved the reliability and lifespan of refurbished GET, aligning performance closer to that of new tools.
• Strengthened customer trust and satisfaction by delivering consistent quality and demonstrating commitment to continuous improvement.

Methods Applied:

• DMAIC Methodology (Six Sigma):
  • Define: Identified frequent GET failures and unplanned downtime due to uncontrolled refurbishment practices as the primary problem.
  • Measure:
    • Collected data on GET failure rates, refurbishment cycles, and the quality of scrap materials used.
    • Quantified the impact on operational efficiency and costs associated with downtime and replacements.
  • Analyze:
    • Assessed the correlation between the number of refurbishment cycles and GET performance.
    • Identified that excessive refurbishment beyond material capability led to decreased performance and failures.
  • Improve:
    • Established refurbishment limits, setting a maximum of three cycles per core to optimize performance.
    • Implemented quality assessments of scrap materials and introduced tracking mechanisms through identification marks.
    • Standardized refurbishment processes with clear guidelines to enhance consistency and quality.
  • Control:
    • Monitored GET performance post-implementation using the tracking system to ensure sustained improvements.
    • Regularly reviewed data and made adjustments based on ongoing analysis to maintain optimal performance.
• Lean Principles:
  • Reduced waste by setting limits on refurbishment cycles, preventing overuse of scrap materials that led to failures and additional costs.
  • Streamlined refurbishment processes by standardizing practices, improving efficiency, and ensuring consistent quality.
  • Optimized resource utilization by assessing material quality and only refurbishing suitable components.
• Continuous Improvement (Kaizen):
  • Implemented identification marks on refurbished GET to monitor refurbishment cycles and track performance over time.
  • Regularly reviewed and adjusted refurbishment limits and processes based on performance data and feedback.
  • Encouraged a culture of continuous improvement within the refurbishment team, fostering innovation and accountability.
• Root Cause Analysis (RCA):
  • Identified that uncontrolled use of scrap materials and lack of refurbishment limits were causing decreased performance and shorter lifespans of refurbished GET.
  • Determined that the absence of tracking mechanisms led to excessive refurbishment cycles beyond the material's capability.
  • Addressed underlying issues by implementing controls and quality assessments to prevent recurrence.
• Data-Driven Decision Making:
  • Used data collected from boneyard analyses and performance tracking to inform decisions on refurbishment limits and process improvements.
  • Analyzed wear patterns and failure modes to enhance understanding of GET performance over multiple refurbishment cycles.
• Quality Assurance and Control:
  • Assessed the quality of scrap materials before refurbishment to ensure only suitable components were used.
  • Implemented standardized procedures to maintain high-quality workmanship and consistent outcomes.
  • Conducted inspections and testing on refurbished GET to verify performance standards were met.
• Collaboration and Communication:
  • Worked closely with the customer to gain approval for the refurbishment limits and to align on quality expectations.
  • Communicated findings and improvements to stakeholders, fostering transparency and trust.
  • Collaborated with the refurbishment team to implement changes effectively and efficiently.
• Risk Management:
  • Mitigated risks associated with GET failures by establishing refurbishment limits and quality controls.
  • Monitored ongoing performance to identify potential issues early and take corrective action promptly.

Leveraging AI to Optimize GET Refurbishment Practices

Analysis: How AI can assist in enhancing GET refurbishment practices today.

AI Applications Ranked by Impact and Viability:

Notes:

• High-Impact Applications: AI-powered predictive maintenance and quality assessment directly improve performance and reduce costs.
• Moderate Viability Applications: Intelligent tracking and AI-based process optimization enhance efficiency but may require significant initial investment.
• Lower Viability Applications: Generative AI for process innovation has potential but may face challenges in practical implementation.

This approach demonstrates how AI technologies can be integrated to optimize GET refurbishment practices effectively.

Cost Reduction through GET Refurbishment and Recycling

Situation: Global supply issues of Ground Engaging Tools (GET) led to excessive spending and a high generation of scrap due to severe abrasion. This situation resulted in increased costs and challenges in maintaining adequate GET supplies for mining operations.

Task: Implement a refurbishment program for GET by recycling scrap from plates and castings to reduce costs and promote sustainability, ensuring the refurbished tools meet the same performance standards as new ones.

Action:

• Classified scrap materials into plates and castings to organize processing and maximize material reuse.
• Collaborated with a university laboratory to conduct metallurgical analyses of the scrap materials, verifying their suitability for refurbishment.
• Developed specialized welding procedures and protocols to effectively join scrap materials without compromising structural integrity or quality.
• Manufactured refurbished GET components, strictly adhering to the original design specifications to ensure performance parity with new tools.
• Implemented quality assurance measures, including testing and inspections, to validate the performance of the refurbished GET.

Results:

• Achieved annual savings of $1 million for the customer by reducing the need for new GET purchases.
• The project was recognized as a finalist for the Gold Idea award, highlighting its innovation and impact.
• Refurbished GET demonstrated performance equivalent to new GET, meeting all operational requirements.
• Promoted sustainability by reducing waste and recycling materials that would have otherwise contributed to environmental impact.

Methods Applied:

• DMAIC Methodology (Six Sigma):
  • Define: Identified high costs and excessive scrap generation due to GET wear and supply chain disruptions.
  • Measure: Quantified the volume of scrap materials and calculated associated costs and potential savings.
  • Analyze: Assessed the feasibility of refurbishing scrap materials through detailed metallurgical analysis and determined the root causes of premature GET wear.
  • Improve: Implemented refurbishment processes, including developing specialized welding procedures and manufacturing protocols to produce refurbished GET that met quality standards.
  • Control: Monitored the performance of refurbished GET through rigorous testing and quality assurance measures to ensure they maintained performance equivalent to new tools.
• Lean Principles:
  • Eliminated waste by recycling scrap materials, reducing disposal costs, and minimizing environmental impact.
  • Optimized processing workflows by effectively classifying and organizing scrap materials, streamlining the refurbishment process.
• Continuous Improvement (Kaizen):
  • Engaged in ongoing collaboration with the university laboratory to refine metallurgical analysis techniques and improve material assessments.
  • Iteratively developed and tested welding procedures to enhance quality and efficiency in joining scrap materials.
• Root Cause Analysis (RCA):
  • Identified that excessive abrasion was causing premature GET wear, leading to high scrap generation and increased costs.
  • Determined that global supply chain disruptions were inflating costs and causing delays in obtaining new GET, necessitating an alternative solution.
• Sustainability Practices:
  • Promoted environmental responsibility by implementing recycling practices and reducing the carbon footprint associated with manufacturing new GET.
  • Aligned with corporate sustainability goals and customer expectations for environmentally friendly solutions.
• Collaboration and Partnership:
  • Established a partnership with an academic institution to leverage expertise in metallurgy and materials science.
  • Fostered a collaborative environment that encouraged knowledge sharing and innovation.

Leveraging AI for GET Refurbishment and Recycling in Modern Operations

Analysis: How AI can assist in solving the GET refurbishment and recycling problem today.

AI Applications Ranked by Impact and Viability:

Notes:

• High-Impact Applications: Predictive analytics, AI vision systems, and AI welding optimization directly enhance cost reduction and operational efficiency.
• Moderate Viability Applications: Digital twins and NLP require initial investments in infrastructure but provide long-term scalability.
• Low Viability Applications: Generative AI for metallurgy is limited by the need for domain expertise and validation of AI-suggested solutions.

This approach showcases how AI can be strategically integrated to tackle complex operational challenges effectively.