CR Masterclass 1 - GET Improvement
Summary
TLDRIn this masterclass, Quintin Ninaber, GM of Product Management at CR, discusses how Ground Engaging Tools (GET) can boost productivity by 5% and reduce total cost of ownership. He explains the evolution of GET from simple steel to a highly engineered system, crucial for excavators and loaders. The focus is on tooth design, lip shrouds, and retainers, which directly affect productivity, maintenance, and costs. The introduction of cast lip systems for 100-400 ton excavators and wheel loaders is highlighted as a significant innovation, offering durability, reduced maintenance, and potential for increased productivity. The session concludes with a real-world example demonstrating the impact of these advancements on operational efficiency and cost savings.
Takeaways
- 🔨 GT (Ground Engaging Tools) is a highly engineered system that goes beyond being just a piece of steel, directly impacting excavator productivity and total cost of ownership.
- 🦷 The design of GT teeth is crucial for productivity as they break ground and open the cleavage plane, affecting machine fill times, GT consumption, and dig energy.
- 💼 Lip shrouds play a significant role in productivity by directing material into the bucket efficiently, which is critical for maintaining cycle times and payload.
- 👄 The lip's profile is essential for dig energy, fill times, and overall durability of the bucket system, with different types of lips suited for different machine sizes.
- 🔩 Retainers are vital for ensuring GT stays attached to the lip and bucket, preventing productivity loss and maintenance costs due to lost or broken GT.
- 📈 Machine productivity is defined by the ability to fill trucks efficiently, with durability and dig efficiency being key factors for effective machine utilization.
- ⏱️ Small improvements in cycle time, such as a one-second reduction, can lead to significant productivity gains, especially on large excavators.
- 🚚 The right bucket size and GT configuration can greatly impact productivity by ensuring efficient filling and higher payloads.
- 🏭 The introduction of cast lip systems represents a significant innovation, offering optimized design, lighter weight, and increased strength, leading to improved productivity and reduced maintenance costs.
- 💡 Advanced monitoring and analysis technologies allow for real-time tracking of productivity improvements, demonstrating the impact of GT design changes on machine performance.
- 🔩 The conversion to cast lip systems can significantly reduce infield maintenance and overhaul costs, potentially saving thousands of dollars per machine per year.
Q & A
What is the main focus of the masterclass presented by Quintin Ninaber?
-The main focus of the masterclass is to discuss how Ground Engaging Tools (GET) can deliver a five percent increase in productivity and improve total cost of ownership in mining operations.
What has the evolution of technology done for Ground Engaging Tools (GET) in the mining industry?
-The evolution of technology has transformed Ground Engaging Tools (GET) from being just a piece of steel to highly engineered tools that can directly impact the productivity of excavators, wheel loaders, rope shovels, and drag lines.
What are the key components of GET that affect productivity?
-The key components of GET that affect productivity include the teeth, lip shrouds, and retainers. These components are crucial for breaking the ground, directing material into the bucket, and ensuring all parts stay attached to the lip and bucket, respectively.
Why are teeth important for productivity in mining operations?
-Teeth are important for productivity because they break the ground and open the cleavage plane, which loosens the material in front of the bucket. If the tooth design is not suitable for the application, it can slow down the machine, increase wear and tear, and cost more in maintenance.
What role do lip shrouds play in the productivity of mining operations?
-Lip shrouds play a significant role in productivity by directing material into the bucket as it moves through the digging phase. Misalignment of planes and surfaces can dramatically impact fill energy, dig energy, and cycle times.
How does the design of the lip affect the overall performance of the bucket?
-The lip serves to hold and point the GET, and its profile is critical to dig energy, fill times, and overall durability of the system. The design of the lip can impact the machine's ability to fill trucks efficiently and effectively.
What are the two main types of lips mentioned in the script, and what are their typical applications?
-The two main types of lips are the traditional platelet style, which is used on excavators below the 400-tonne mark and wheel loaders, and the cast lip, which is used for machines with an operating weight of over 400 tonnes.
How can the design of Ground Engaging Tools (GET) impact maintenance practices and costs?
-The design of GET can impact maintenance practices and costs by ensuring durability and ease of maintenance. For instance, the introduction of cast lip systems can reduce infield maintenance and overall overhaul costs by eliminating the need for weld-on components.
What is the significance of the five percent improvement in productivity mentioned in the script?
-A five percent improvement in productivity means that for every hour of operation, an additional truck can be filled, which translates to significant tonnage moved annually and a substantial increase in operational efficiency.
How does the introduction of cast lip systems contribute to reducing maintenance costs and increasing productivity?
-The introduction of cast lip systems contributes to reducing maintenance costs by eliminating the need for weld-on components, which reduces infield maintenance and overhaul costs. It also increases productivity by allowing for a lighter, stronger design that aligns better with the digging process.
What is the Titan Load Hole Optimization System, and how does it benefit the optimization of Ground Engaging Tools (GET)?
-The Titan Load Hole Optimization System is a tool used to pinpoint key factors for efficient digging and track changes to productivity in real-time. It helps in optimizing the design of GET to ensure efficient digging, proper filling of buckets, and reduced cycle times.
Outlines
🔨 The Role of Ground Engaging Tools (GET) in Productivity and Cost Efficiency
Quintin Ninaber introduces a masterclass on how Ground Engaging Tools (GET) can enhance productivity by 5% and reduce total cost of ownership. GET, once considered just a piece of steel, has evolved into a sophisticated tool impacting excavators, wheel loaders, rope shovels, and drag lines. The session focuses on the critical components of GET, including the lip, lip shrouds, teeth, and retainers, and their impact on productivity. The importance of tooth design is emphasized, as poor design can increase machine resistance, leading to higher wear, higher energy consumption, and slower operation. Lip shrouds are highlighted for their role in directing material into the bucket, affecting digging efficiency. The video discusses how the design of GET components can either optimize or hinder productivity and cost.
🛠️ Enhancing Machine Productivity and Durability with GET
The second paragraph delves into the importance of machine productivity, defined as filling trucks efficiently for as many hours as possible. GET must be designed with durability and maintenance in mind to ensure minimal downtime. The dig efficiency is crucial, with the lip profile and tooth alignment playing significant roles in reducing resistance during the digging phase. The video mentions that even a one-second reduction in cycle time can lead to a 1% increase in productivity. The discussion also covers the importance of bucket size and fill capacity, with a focus on how an optimized GET package can improve fill and mass metrics, potentially increasing productivity by 5%. The introduction of cast lip systems for excavators and wheel loaders is presented as a significant innovation, offering benefits such as lighter weight, better alignment, and increased strength, leading to improved productivity and reduced maintenance costs.
📈 Real-World Impact of GET on Productivity and Cost Reduction
The final paragraph presents a real-world example of a customer who converted their 120-ton excavator from a plate system to a cast lip system, resulting in a 5% decrease in cycle time, a 3% decrease in truck fill time, and a 1% increase in payload. This translated to an additional truck per hour and a 92-ton per hour increase in productivity. The video concludes by emphasizing that GET is now a highly engineered system that directly impacts productivity and total cost of ownership, regardless of the loading tool used. It highlights the importance of durability, reliability, and minimal maintenance in GET design to maximize machine utilization and reduce costs. The session ends with an invitation for questions and a teaser for the next masterclass, which will focus on key design triggers and techniques used to ensure product performance.
Mindmap
Keywords
💡Ground Engaging Tools (GET)
💡Productivity
💡Total Cost of Ownership (TCO)
💡Tooth Design
💡Lip Shrouds
💡Cast Lip
💡Durability
💡Dig Efficiency
💡Bucket Fill
💡Maintenance Practices
Highlights
GT (Ground Engaging Tools) can deliver a 5% increase in productivity and improve total cost of ownership.
GT has evolved into a highly engineered tool impacting productivity on various mining machines.
The teeth of GT are crucial for breaking ground and directly impacting productivity.
Poorly designed teeth can increase machine resistance, leading to higher GT consumption and energy use.
Lip shrouds play a critical role in directing material into the bucket, affecting productivity.
Misalignment of GT components can significantly impact dig energy, fill energy, and cycle times.
The lip of the bucket is essential for holding and pointing GT, and contributes to the bucket's front structure stiffness.
There are two main types of lips: traditional platelet style and cast lip, each suitable for different machine sizes.
Retainers are vital for ensuring GT stays attached to the lip and bucket, preventing productivity loss.
Machine productivity is defined by the ability to fill trucks efficiently for as many hours as possible.
Durability is key for effective machine utilization and reducing downtime for maintenance.
Dig efficiency is where GT can significantly impact productivity by reducing resistance during the dig phase.
A machine is physically digging for only around 40% of the swing cycle, presenting an opportunity for GT to improve productivity.
The right bucket size and filling capacity can greatly impact productivity.
Advancements in monitoring and analysis allow for precise measurement of GT's impact on productivity.
A small design change in a tooth can significantly increase the tons moved by machines.
Cast lip systems offer innovations for excavators and wheel loaders, optimizing design for lighter weight and better alignment.
Product durability is essential for increasing effective machine utilization and reducing maintenance.
Cast lip systems can reduce infield maintenance and total overhaul costs, increasing productivity and reducing total cost of ownership.
A customer case study shows a 5% decrease in cycle time and a 3% decrease in truck fill time after converting to a cast lip system.
GT is a highly engineered system that impacts productivity and total cost of ownership across various loading tools.
CAR SLIP and GT are designed for durability, reliability, and minimal maintenance to maximize machine utilization.
Transcripts
[Music]
thank you for joining our masterclass on
how gt can deliver a five percent
increase in productivity and improve
total cost of ownership
i'm quintin ninaber and i'm the gm
product management here at cr
over the next 15 minutes we will cover
the critical role that gt plays in the
improvement of productivity and the
overall reduction in total cost of
ownership
we will cover the gt itself
and how it can in fact productivity as
well as cover how it can affect your
maintenance practices so you save money
as we work through this session ask
yourself what a five percent improvement
in productivity could mean for your site
or operation
gt is no longer just a piece of steel
that sits on the front of your bucket
with the evolution of technology and the
desire of the mining industry to find
step change wherever we can it has
actually become a highly engineered tool
that can directly impact the
productivity on excavators wheel loaders
rope shovels and even drag lines so what
is get
it's a first bit of steel that breaks
the ground and cuts the path for your
bucket to follow
it's a modular system that allows you to
change the setup to better suit your
specific needs
and the most important of these are the
lip
the lip shrouds the teeth and the
retainers
when you are talking about gt and
productivity there is nothing more
important than the teeth
teeth are the components that break the
ground and open the cleavage plane which
directly impacts productivity because it
loosens the material in front of the
bucket essentially cutting a path for it
to follow
if the design of the tooth is not done
well it will dramatically impact your
fill times because the machine has to
work harder to get through the
resistance
your gt consumption will skyrocket
because the higher resistance means more
friction and wear and finally your dig
energy will increase which impacts the
rest of the machine from fatigue through
to fuel burn
if your tooth design is not right for
your application
it will slow you down and cost you money
on every single pass
following the teeth are the lip shrouds
and you may think that they are just
there to protect the lip from wearing
out as material flows into the bucket
but over the last 12 years we have found
that they play a much more important
role in productivity than first thought
because directing material into the
bucket as it moves through the digging
phase is absolutely critical
using our scale testing facilities and
titan load hole optimization system we
have been able to pinpoint the key
factors that need to be just right to
ensure efficient digging if the planes
and surfaces don't align with each other
and the engagement in digging planes
fill energy dig energy and cycle times
are impacted dramatically it's the key
point of the design that determines if
the material is pushed away
or underneath the bucket instead of
filling it smoothly again getting just a
single element of the design wrong has
the ability to slow you down reduce your
payloads and cost you in maintenance
dollars
the lip shrouds are attached to the lip
which is attached to the front of the
bucket
the lip serves to hold and point the gt
but it also plays a key role in
stiffening the front structure of the
bucket the lip profile is critical to
dig energy fill times and over overall
durability of the system
there are two main types of lips the
traditional platelet style
which is fabricated steel plate with
adapters welded on
these are the typical arrangements you
will see on excavators below the 400
tonne mark and also wheel loaders then
there is the cast lip this is the lip
that is completely cast in a single
piece with integral noses these are your
standard type of lips for machines with
an operating weight of over 400 ton
the retainers or locks are actually as
important as the other three
because they ensure that all the gt
stays attached to the lip and the bucket
when gt is lost or broken it can have
devastating effects on productivity
maintenance and downstream costs on
average a crusher event that is due to
gt has a downtime period of 12 to 24
hours
so you might be wondering just how gt
can impact productivity or maintenance
or even total cost of ownership
to answer that question we need to know
what machine productivity actually is
and at its core machine productivity is
all about filling as many trucks per
hour for as many hours as possible
so durability is absolutely important
it's the metric we use to define how
strong
well-designed and reliable a component
is
and it is the key driver for effective
utilization on any machine
if the machine is down because you're
changing teeth welding adapters or
checking for wear parts then your
machine is not filling trucks and if
it's not filling trucks it's not
productive
gt must be designed with durability and
maintenance requirements in mind
ensuring that it fits how it's supposed
to
lasts as long as it's designed to and
only comes off when you wanted to
it's absolutely critical because keeping
that machine digging is key
another important part to consider is
the dig efficiency
because it's an area where gt can make
the most significant impact the profile
of the lip the shape of the teeth and
the alignment of all the surfaces must
be just right to ensure that the machine
experiences as little resistance as
possible when it is in its dig phase
do you know that the machine is only
physically digging for around 40 percent
of the swing cycle
this means there is a massive
opportunity for gt to improve or impact
productivity
and it is crucial that the digging
portion of any swing cycle is as fast
and smooth as possible
decreasing cycle time by as little as
one second can improve productivity by
over one percent that doesn't sound like
much but on a 700 ton excavator that can
be as much as
000 tons annually
there is no point having the smoothest
digging if your bucket can't fill
properly or if its capacity is too low
having a bucket that is the right size
and filling correctly can have a much
more significant impact on productivity
the less steel you have in the bucket
and the gt the more actual material you
can pick up
an excellent gt package will facilitate
both the fill
and mass metrics
increasing the fill factor by only one
cubic meter can equate to an increase of
five percent overall tons move
this can be as much as six hundred
thousand tons annually on that same
machine we mentioned before
the beauty of having access to the
latest technological advancements in
monitoring and analysis means we can
really see the impact small changes can
have on a machine's productivity and
total cost of ownership when we
developed a new sp style tooth we were
able to put it up against the standard
ra style tooth in the real world and
using our industry-leading titan load
hole optimization system we were able to
track the changes to productivity in
real time
we found that this relatively small
design change had a significant impact
on the tons moved by the machines
payload increased by three percent build
time decreased by four percent and
ultimately resulted in an increase in
five percent productivity
five percent improvement in punish just
by changing the tooth imagine what a
tooth change can do for your site
without a doubt the biggest innovation
in this space is the introduction of
cast lip systems for excavators in the
100 to 400 ton class wheel loaders and
even for rope shovels
the primary premise being that by
removing the weld on or mechanical
adapters and casting a complete lip it
really allows you to optimize the design
if you do it right you can eat your cake
and have it
you can put material strategically to
ensure a much lighter overall weight you
can align the gt better in both the
shroud sections and the noses
and you can make it significantly
stronger
lighter by up to 10 percent stronger by
30 percent with this combination not
only are you closer to your 5
improvement in productivity but you are
so much closer to that significant
reduction in your maintenance costs
this brings us to ask the question how
can you increase the as many hours as
possible part of the equation and the
answer is product durability
every application is generally different
to some extent and i know you're
wondering how can a lib system possibly
increase effective utilization
regardless of application there are some
universal truths like welding components
requires preventative maintenance teeth
need to be changed
buckets need to be inspected and cracks
must be repaired and by eliminating just
one of these completely we can reduce
the amount of time money and safety risk
car slips gives us the opportunity to do
exactly that by removing the need for
weld on components altogether from wear
package right through to adapters it
means that an entire portion of the
maintenance element is removed
this not only increases the opportunity
to operate more effectively it also
dramatically reduces the total cost of
ownership
for instance when a site converts their
100 to 400 ton excavator over to a cast
lip they remove as much as 90 percent of
the infield maintenance and up to 65 of
total overall
overhaul costs
depending on the application this can be
up to 130 000 per machine per year so if
you're only running five of these
machines on your site that's over half a
million dollars you're leaving on the
table
if you combine the smarts
and the geometry
and the optimization of a cast lip you
can increase productivity by more than
five percent and you can reduce your
overall cost of ownership
do you think your sites could benefit
from an increase in productivity and a
decrease in maintenance
let's look at an example of when a
customer converted their platelet system
over to a car slip system on their 120
ton excavator
again we used our titan load hole
optimization system to track the
performance of the conversion in real
time we found that cycle time decreases
on average by five percent
truck fill time decreases by three
percent and payload increased by one
percent
this equates to an additional truck per
hour and in this case 92 tons per hour
but that's not the biggest story for
this customer combining the durability
of the car's lip system and the
reliability of the gt the customer
reduced their total cost of ownership by
65
and they were able to increase their
productivity by 92 tons per hour
gt is no longer just a piece of steel
whose value can be measured on a dollar
per kilogram basis it's a highly
engineered system that directly impacts
productivity and total cost of ownership
it doesn't matter which loading tool you
are using whether it's a 100 ton
excavator an ultracraft face shovel the
world's largest drag lines rope shovels
or even wheel loaders gt will impact
your operation
car slips and gt are a fully integrated
modular technology that must be designed
and manufactured to ensure that the
machine is able to be effectively
utilized for as many hours as possible
it has to be durable and reliable to
withstand the harshest of mining
conditions
it must be streamlined and lightweight
to ensure that machines can fill their
buckets as fast and effectively as
possible
it has to remove as many elements of
maintenance and handling as possible
when you get it right you can capture
that five percent or more increase in
untapped productivity while at the same
time reducing the maintenance
requirements to cut your total cost of
ownership thank you and i hope you
enjoyed today's session we will be
taking questions shortly and we look
forward to seeing you at our next master
class on the 11th of june when our
engineering design team will show you
the key car slip and gt design triggers
engineering techniques and tools we use
here at cr to ensure our products help
to maximize performance to increase
productivity while cutting total cost of
ownership
bye
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