AMT Asset Mangement Tool - 2012

AMT Asset Management Tool
2012
www.isipl.com iSolutionsAMT for SAP
Introduction
AMT 1
Contents
iSolutions Introduction
What is AMT
Workflow Management

Introduction
AMT 2

Introduction
AMT 3
Providing organisations with the systems and expertise

to optimise asset returns
Asset management expertise Consulting + Software (AMT)
In-house software development and support
Strong presence in capital intensive industries Mobile + Plant

Introduction
AMT 4
A Global Client Base
Argentina Ivory Coast

Australia Japan
Botswana Mali
Canada Mongolia
Chile Peru
China New Caledonia
Columbia New Zealand
France Norway
Germany South Africa
Ghana United Kingdom
India USA
Indonesia Zambia
Offices
Sites

Introduction
AMT 5
AMT system of choice
AMT is used to manage or track +50%
of the worlds large mobile mining equipment
Used on +200 sites globally Batu Hijau, KPC, Escondida, Freeport, Yanacocha, KCGM, Telfer, Blackwater,
Mopani
Mining Companies - Newmont, Wesfarmers, Glencore, Peabody, Newcrest, BHP Billiton, Xstrata
Cat Dealers 5 of the top 6 Cat mining dealers use AMT (WesTrac, Hastings Deering, Trakindo, Finning, Barlows)
Komatsu globally
Hitachi Australia, Africa, Indonesia
Mining Contractors - Downer EDI Mining, Moolmans

Introduction
AMT 6
Products and Services
AMT Software Comprehensive asset management software
Framework Defining, reviewing and optimising the MOS (Management Operating System)
Equipment modelling Feasibility studies

Consulting Maintenance Maturity Reviews Operational Readiness
Training Developing maintenance managers

Introduction
AMT 7
AMT Configurations
AMT AMT with all features, flexible configuration and integration
AMT - One Standardised AMT, limited to core features streamlined deployment
AMT - Focus Advanced functionality around modelling, budgeting and condition based maintenance
AMT - Enterprise For multi-nationals requiring global data consolidation and knowledge sharing
AMT with specialised OEM functionality around contract management, component

AMT for OEMs capacity management and product support marketing
AMT for SAP/Oracle AMT configured to enhance SAP/Oracle, includes certified SAP/Oracle integration
AMT with specialised Contractor (Plant Hire / Rental) module - plant rate development,
AMT for Contractors plant invoicing, plant performance analyses, component based depreciation

Introduction
AMT 8
What is AMT?

Introduction
AMT 9
What is AMT?
An Integrated Asset Management Tool
Maintenance Work Management
Maintenance Decision Support
Management Reporting
Budgeting and Forecasting
Manages all of your assets
Fully Integrated to your Enterprise Systems

Introduction
AMT 10
Benefits for Operations Team
Easy to Use / Quick Adoption
Daily Planning Efficiency
Performance Reporting
Resource Planning
Work Package Delivery

Introduction
AMT 11
Benefits for Management Team
Visibility and Control
Accurate Budgets
Component Optimisation
Business Planning

Introduction
AMT 12
Why AMT?

Introduction
AMT 13
Control Capital Investment
Enabling Higher Utilisation to Reduce Number of Units
Optimise plant availability
Reduce demand on capital
Reduce demand on leased equipment
The Right Replacement Time

Determines the optimal (economical) replacement point
Life cycle costing and integrated Financial and Operational management
Within the life cycle of the plant and/or within the context of the contract

Introduction
AMT 14
Profitability
Cost Control
Accurate cash flow forecasting
Zero-based budgeting
Operating cost analysis and optimisation
Cost Reduction
Minimise maintenance intensity
Optimise resources capital, labour, materials, tools and equipment
Optimise inventory by understanding demand

Introduction
AMT 15
Improve Asset Performance
Improve Availability
Move toward condition based maintenance
Reduce maintenance frequency
Ensures maintenance conducted only when required
Improve Reliability
Practical approach to reliability
Targeted condition based alerts
Optimise maintenance strategy

Introduction
AMT 16
Workflow Management

Introduction
AMT 17
Workflow Management
Strategy Long Term Short Term Work

Asset Register Scheduling Execution
Definition Planning Planning Finalisation
Asset listing, functional hierarchy

Asset Register Flexible utilisation profiles and application severity assumptions
Asset Financial Ledger - capital asset register and component capitalisation (including depreciation)
Define the base maintenance plans (strategy tasks) which drives the maintenance schedule and life cycle costing
Standard Jobs
Strategy Definition
Job Instructions (Electronic workscopes or attached documents)
RCM module for comprehensive strategy definition
Manage and optimise component changeout schedules, graphical drag n drop gantt charts
Long-term Planning
Forecast reports for availability, productivity, costs, components, parts, labour and consumables requirements
Backlog management, PM and Inspections control, daily planning and scheduling, Job Folder creation, raising
Short Term Planning POs
Labour scheduling and resource levelling

Introduction
AMT 18
Workflow Management
Strategy Long Term Short Term Work

Asset Register Scheduling Execution
Definition Planning Planning Finalisation
Electronic shift log, quick access to equipment history and component status, downtime capture and analysis
Update status of work, assign labour, create breakdown workorders
Execution
Integration to Dispatch systems
Produce daily log reports and daily KPI reports
Mobility solution enables service personnel to perform work remotely, complete checksheets, capture job
details, create new defects etc.
Mobile
Operates in tablet or PC.
Technical Advisor assist with diagnostic of defects
Capture job information including failure codes, condition monitoring data, attach documents and component
Work Finalisation
tracking information.
Imports and interprets condition monitoring data, triggers creation of workorders and emails, monitors actions,
Condition Based Maintenance displays fleet condition. Consolidates condition monitoring data from all sources. Drives both strategy and daily
responses.

Introduction
AMT 19
Overview
AMT Modelling enables the development of detailed life-
cycle costing models to support a range of analyses
Equipment/fleet selection
Feasibility budgets
Equipment preparation
Forecasting optimal replacement points
Evaluate fleet/contract extensions
Equipment rate calculations (OEMs / Contractors)

Introduction
AMT 20
Key features
Comprehensive LCC structure

Fleets
Equipment/Asset details
Strategy Tasks
Standard Jobs Life-cycle costing
Job Instructions (Costs, Availability, Labor, Components,
Consumables)
Reliability Assumptions
Operating Assumptions Maintenance strategy definition
Utilisation
Application Severity Detailed maintenance plans
Productivity

Introduction
AMT 21
Key features
Usability
Streamlined wizards to copy and create multiple equipment
Flexible editing
Multi-edit equipment and strategy tasks
Copy and paste
Ability to import and export templates from Excel
Comprehensive reporting and analyses

Introduction
AMT 22
Key features
One solution to support the end to end modelling process
Equipment Equipment Fleet Feasibility Maintenance

Centrelines Evaluation Selection Budgets Preparation
Additional features
Evaluate optimal replacement points for existing equipment
Evaluate contract extensions
Calculate plant rates (Contractors/Rental/Plant Rates)
OEM contract tendering

Introduction
AMT 23
Benefits
Standardisation
Consistent format for equipment evaluation and feasibility budgeting
Consistent structure of maintenance plans once equipment purchased
Accuracy
Improved accuracy of feasibility budgets
Efficiency
Reduced time to create feasibility budgets
Builds a knowledge base that can be leveraged

Introduction
AMT 24
Proven Performance
OEMs
Used by Cat Dealers, Bucyrus, Komatsu and Hitachi to prepare contract tender rates
for MARC contracts
Mining Companies
Used by BHP Billiton, Newcrest, Peabody and Newmont for feasibility budgeting and equipment
evaluation (i.e. BHP Billitons Olympic Dam Expansion project)
Mining Contractors
Used by Downer EDI, John Holland and Moolmans to prepare plant rates

Introduction
AMT 25
Example of outputs
1. Cost Analyses

Introduction
AMT 26
Example of outputs
2. Availability & Productivity forecasts

Introduction
AMT 27
Example of outputs
3. Cost / UOM Analyses (i.e. CPH or CPT)

Introduction
AMT 28
Example of outputs
4. Resource Forecasts
Components Labour and People
Consumables

Introduction
AMT 29
Example of outputs
5. Equipment Benchmarking
Life Cycle Cost per Hour by Model
Life Cycle Cost per Tonne Comparison

Introduction
AMT 30
Example of outputs
6. Optimising Equipment Replacement Points
Plots the expected value in

components over time.

Introduction
AMT 31
Example of outputs
7. Detailed Feasibility Budgets
Create multiple versions
Includes:
Site Overheads
CAPEX
Productivity and utilization
Flexible analysis and reporting

Ability to compare budgets

Introduction
AMT 32
Focus on Components
Typical analyses of maintenance costs

100%
Indirect Costs Indirect Costs
80% Major Components on Major
Other Equipment Other Equipment Equipment account for 25-30% of
maintenance costs
60%
Other Costs Highest risk area of maintenance

40%
Major Equipment High variability
20% Top 5-8
Components

Introduction
AMT 33
How does it work?
Focus on Mobile equipment
Initial Setup
Major equipment registered in AMT
Projections setup with:
Major Components setup as Strategy Tasks (last performed, frequency, changeout cost, labour hours)
Remaining equipment costs split into 3-8 groupings (PMs, Misc., Electricals)
Remaining maintenance costs setup as Overheads in AMT
Ongoing
Component Changeout schedule manually maintained
(i.e. changeout schedule optimised, updated for changeouts or changes to the scheduling frequency
Utilisation readings for major equipment manually entered once a month
Summary of costs manually uploaded into AMT once a month (this is OPTIONAL)

Introduction
AMT 34
Is it practical?
If a site has 50 major mobile equipment then
Approximately 13 Component Changeouts per month

(8 components done every 2.5 years)
50 usage readings to enter each month
Maintain component changeout schedule

Not ideal to maintain the data
Refine forecasting parameters as required manually but:
Import costs each month (optional) - Still less time than

maintaining multiple Excel
sheets
- Benefits of quick
2-3 days of work per month
deployment

Introduction
AMT 35
Why AMT?
Structured database Single tool, multiple user access
The LCC incorporates zero based budgeting, risk, reliability, application severity and escalation
Enhanced Accuracy to provide accurate forecasts
AMT provides a single solution for budgeting, resource forecasting, equipment evaluation,
One solution CAPEX forecasting
Increased efficiency, reduces multiple Excel sheets
AMT provides unique functionality particularly around risk assessment, optimising

maintenance plans, resource planning and component management
Unique functionality
Enables multiple sets of maintenance plans to be held against one asset (i.e. original
assumptions when asset was purchased)
User friendly, intuitive functionality

User friendly
Dashboards and alerts

Introduction
AMT 36
Dynamic Life-cycle costing
Dynamic life-cycle costing is the process of
forecasting every maintenance event for an
asset to the end of its life, in real time.
Together with its actual history it forms the full
life-cycle view of an asset.
LCC = Actuals + Forecast
Life-cycle costing covers not just costs but
utilisation, productivity and resource
requirements (labour, components, parts and
consumables)
Enables proactive decision making

Introduction
AMT 37
The following processes are dependent

on life-cycle costing Risk Management
Strategy Optimisation
Without a forward looking view it is not Resource forecasting

possible to adopt a proactive approach Economic life determination
to asset management Equipment evaluation
Forecasting & Budgeting

Introduction
AMT 38
Advanced features
Forecasting accuracy, calculations incorporate:
Planned and unplanned work
Factor in Risk
Reliability assumptions
Forecast utilisation
Application severity
Escalation
Multiple Projections
Multiple projections (sets of maintenance plans) can be housed for a single asset
Enables features such as what-if analyses, benchmarking against industry templates or original purchase
assumptions

Introduction
AMT 39
Flexible reporting and analytics
Life Cycle Cost Summary
Life Cycle Cost Summary is a text report comparing Cost
to Date and Future Costs by Task and Sub-system
between Budget and Current projections
PCV Chart
Line chart that allows users to tailor a report which
compares the current and projected costs of
different projections
Projection Summary
Report gives an overview of the costs for the
equipment by projected task and sub-system
Cost per Interval

Allows users to nominate a period of
hours to analyse what equipment
costs will fall in that timeframe

Introduction
AMT 40
Long-term Planning
Flexible planning grids
Shows related info

Risk, Condition, Budget
performance
Updates SAP

Introduction
AMT 41
Long-term Planning
Resource forecasting
Labor
Components
Consumables
Costs
Utilization
Availability

Introduction
AMT 42
Budgeting
1) Preparing Budgets
Automated routine to prepare a budget <5 minutes
Budget is a snapshot of live Dynamic LCC
Includes Capex, Operating Costs (direct & indirect), Utilisation
Can create, save a copy multiple budgets

Introduction
AMT 43
Budgeting
2) Analyzing and refining Budgets

Flexible reporting and analyses
Apply manual edits and over-rides
Flex budgets assess impact of
different operating schedules
Apply escalations
Compare budgets

Introduction
AMT 44
Budgeting
3) Reviewing actual performance vs. budget

Live dashboard grids to highlight
exceptions
Flexible reporting to analyze and
drill down on variances
Projection of expected variance at
year end
Compliance to plan reporting

Introduction
AMT 45
Equipment Benchmarking
Benchmark
Life-cycle cost
Cost per Unit of Measure
Cost per Hour
Cost per Tonne
Discounted Cash Flow
Discounted Cost per Unit of Measure
Benchmark live equipment against Centrelines (templates)
Cost per interval comparison
Cost type comparisons

Introduction
AMT 46
Life Optimisation
Forecasts the aggregated value

in components for equipment
What is the best time to

dispose of my assets?
Identifies optimal replacement points

Introduction
AMT 47
Product Problem Management
EM Issues Module
Ability to log and track resolution of product
issues
Structured resolution process
Reference details on the issue and corrective
action
Can attach documents
Can track impact of issues (costs and downtime)
Can create corrective notifications/ workorders

for the planners
Builds a knowledge database

Introduction
AMT 48
CBM
Condition Based Maintenance

Introduction
AMT 49
CBM is the process of
Reliability Analyses
interpreting Condition Analyse historical data to refine
strategy & assumptions
Monitoring data against
reliability assumptions to
optimize maintenance
RCM Interpretation Maintenance Planning
decisions Define maintenance strategy Interpret CM results against the Execute required tasks and
and CM interpretation RCM assumptions to determine capture transaction details
rules action required
Condition Monitoring
Monitor specific failure
indicators

Introduction
AMT 50
Maintenance CBM brings

Fleet Condition Component
Messages Emails Planning &
Monitoring Change-outs
Execution Technology (live RCM
architecture)
Leverages IP
Medium High
Trending
Alerts Alerts
Integration to enable
rapid response &
efficiency
CBM
Condition Monitoring
L1 Interpretation L1 Interpretation L1 Interpretation
Oil Analysis VIMS Vibration Analysis Inspections

Introduction
AMT 51
CBM Structure
Forecasts &
Budgets
One integrated solution
LCC ERP RCM assumptions impact LCC
LCC drives forecasting & budgeting
Optional live connection with ERP

RCM

Introduction
AMT 52
Process & Outputs
Automated process for efficiency
Dashboards to monitor fleet condition
Quick drill down to supporting data
Interprets CM data against your RCM
profile
Leveraging the IP in the organisation
Optimising maintenance decisions
Prevent failures
Optimise component lives

Introduction
AMT 53
Reliability Analyses
Flexible analyses to improve the accuracy of reliability assumptions
Trends the condition monitoring

data leading up to failures

Introduction
AMT 54
AMT Mobile
Optional mobility solution
Electronically complete inspections
Operates in a disconnected mode
Tablet/touch screen option
Check in inspection data
Feeds CBM module
Displays Action Dashboard in AMT

Introduction
AMT 55
Framework

Introduction
AMT 56
Framework
A structured, measurable process for
standardising and improving asset
management
Process mapping
Defining best practices
Aligning organisation structures & employee

descriptions
Defining performance measurements

High Costs No Surprises Competitive Advantage Best in Class
Impact
Maintenance Maturity reviews High Overtime Cost Competitive Efficiency
Crisis Quality Learning CBM
Driving continuous improvement Responsive

High Overtime
Discipline
Plan
Proactive
Value Focus
ROC
Strong R&D focus
Culture
Independent Control Employee Dev. Invest in technology
Low Morale Centralise to leverage IP

Introduction
AMT 57
Consulting Services

Introduction
AMT 58
Asset Management Consulting
Consulting services cover
Equipment Evaluation
Feasibility Studies
Maintenance Development / Operational Readiness
Strategy Development
Maintenance Maturity Reviews
Why iSolutions
Library of life cycle cost templates for common equipment
Proven evaluation tools (AMT Modelling, Framework)
Experienced consultants
www.isipl.com Contents iSolutionsAMT for SAP

Introduction
AMT 59
Operational Readiness
A comprehensive toolkit to help with all stages in a new mine or
expansion project
Detailed procedures, templates &

check lists for each step
Used by Newmont Globally for new

project development
Documented Process
Specialised modelling software

Introduction
AMT 60
Training

Introduction
AMT 61
Equipment Management Courses
Equipment Management Fundamentals
Framework Equipment Management Process
Equipment Management Processes, Site Assessments, Organizational structures
Maintenance Strategy
Explains basic principles and provides a structured approach to developing and optimizing a
maintenance strategy for equipment.
Incorporating the RCM principles as part of maintenance strategies.
Determining safety and environmental impacts of maintenance plans

Introduction
AMT 62
Equipment Management Courses
Life Cycle Costing of Large Mining Equipment
How to apply life cycle costing (LCC) methods to mining equipment, and to assess
these investments using reliable financial modelling and sensitivity analysis.
Understand the principles and application of life cycle management.
Discuss options for improving equipment performance and productivity.
Mining Fleet Feasibility Studies

Modelling the economic life of mining equipment
Using LCC principles, covering key financial, commercial and physical aspects
Specific methods for acquiring and operating these vehicles to full advantage.
Introduces a proven database tool to assist the development of life cycle models

Introduction
AMT 63
Recent Projects & Clients

Introduction
AMT 64
Client List
Atlas Copco Komatsu
BHP Billiton Moolmans Mining
Banks Mining Glencore Mopani Copper
Batu Hijau GyM Peru
Bucyrus Equipment Mt Arthur Coal Pty Ltd
Caterpillar + Dealers Mitchell Corp.
Curragh Mine Moolmans Mining
Downer EDI Mining Newmont Mining Corporation
Fortescue Metals Group Newcrest Mining Limited
Glencore Prodeco SA Ngarda Mining and Civil
Hitachi Mining & Construction Olympic Dam Corporation
Minera Yanacocha S.R.L. Stracon Limited
John Holland Mining Zululand Anthracite Colliery

Introduction
AMT 65
Recent Projects
Site process review -Tanami Electric haul truck life cycle costing GE
Self perform vs. owner study - Yanacocha Life cycle data development Freeport
Maintenance benchmarking Trakindo Strategy development workshop Westrac
Maintenance benchmarking Liebherr MARC tender documentation Copper Mine
Haul truck condition assessment - Freeport Equipment benchmarking Newcrest
HME contract review - Pilbara Iron Feasibility study New BHP Billiton Mine
Executive workshop Terex USA Underground equipment LCC MAC
Contract management tool Caterpillar Life cycle cost model development - FMGL
Maintenance benchmarking Newmont Equipment selection Australian gold mine
Equipment Management Course Newmont MARC vs. Owner Study - Telfer

Introduction
AMT 66
What Our Customers Have Said
Of all the systems we looked at AMT was clearly the best tool. AMT
was the strongest across all areas of our business
Chris Goodwin, Maintenance Manager Curragh North Coal Mine
AMT assists Newmont in determining the optimal economic life of the

assets as well as more accurately planning and forecasting availability,
components, resources, costs and consumables
Mike Wundenberg Business Excellence Group, Newmont Mining

Introduction
AMT 67
Contacts
Stuart Burckhardt Graeme Elgie
Chief Operations Officer Managing Director
(T) +61 2 9966 9096 (T) +61 2 9966 9096
(M) +61 413 353 368 (M) +61 400 24 0104
(E) stuart.burckhardt@isipl.com (E) graeme.elgie@isipl.com

Introduction
AMT 68

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AMT Asset Management Tool

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

Providing organisations with the systems and expertise

Asset management expertise Consulting + Software (AMT)

In-house software development and support

Strong presence in capital intensive industries Mobile + Plant

www.isipl.com iSolutionsAMT for SAP

Argentina Ivory Coast

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

AMT Software Comprehensive asset management software

Equipment modelling Feasibility studies

Training Developing maintenance managers

www.isipl.com iSolutionsAMT for SAP

AMT AMT with all features, flexible configuration and integration

AMT - One Standardised AMT, limited to core features streamlined deployment

AMT with specialised OEM functionality around contract management, component

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

Maintenance Decision Support

Budgeting and Forecasting

Manages all of your assets

Fully Integrated to your Enterprise Systems

www.isipl.com iSolutionsAMT for SAP

Easy to Use / Quick Adoption

Daily Planning Efficiency

Work Package Delivery

www.isipl.com iSolutionsAMT for SAP

Visibility and Control

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

The Right Replacement Time

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

Strategy Long Term Short Term Work

Asset listing, functional hierarchy

www.isipl.com iSolutionsAMT for SAP

Strategy Long Term Short Term Work

www.isipl.com iSolutionsAMT for SAP

Forecasting optimal replacement points

Evaluate fleet/contract extensions

Equipment rate calculations (OEMs / Contractors)

www.isipl.com iSolutionsAMT for SAP

Comprehensive LCC structure

www.isipl.com iSolutionsAMT for SAP

Copy and paste

Ability to import and export templates from Excel

Comprehensive reporting and analyses

www.isipl.com iSolutionsAMT for SAP

Equipment Equipment Fleet Feasibility Maintenance

www.isipl.com iSolutionsAMT for SAP

Consistent structure of maintenance plans once equipment purchased

Builds a knowledge base that can be leveraged

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

www.isipl.com iSolutionsAMT for SAP

Components Labour and People

www.isipl.com iSolutionsAMT for SAP

Life Cycle Cost per Hour by Model