Scale Testing

Summary

Scale testing is a cost-effective and time-efficient method for validating designs on smaller machines that mimic real-world scenarios. It allows for quick adjustments and testing without risking actual operations, particularly beneficial for large capital purchases like excavators and buckets. By setting up a scaled pit that replicates real-world conditions, companies can optimize solutions and ensure they translate effectively to the field. This method stands out as it provides a competitive edge by offering a level of testing and validation that most competitors lack, leading to more accurate and reliable results for customers.

Takeaways

• 🔍 Scale testing is a method used to simulate real-world scenarios in a smaller, controlled environment to validate designs efficiently.
• ⏱️ It offers a cost-effective and time-efficient way to test and adjust designs without risking actual operations.
• 💡 The process allows for quick iterations and improvements, which is especially valuable for innovative or new designs.
• 💼 It's particularly useful for large capital purchases like excavators, where downtime can be very costly.
• 🏗️ The setup involves creating a scaled pit that mimics real-world conditions such as bench heights, particle sizes, and material densities.
• 📏 Machine constraints are scaled down to match the pit, ensuring that parameters like wear, bucket fill, and void detection are accurately represented.
• 📹 Visual metrics and cameras, including viewing ports in buckets, are used to monitor the testing process.
• 💾 Real-time data from sensors is recorded using systems like the Titan, which allows for detailed analysis of machine performance.
• ⚙️ It's crucial to avoid over-customization that makes the solution too specific and not applicable to other scenarios.
• 🏅 Scale testing gives the company a competitive edge as most competitors lack this level of validation before market release.
• 📈 By optimizing solutions through scale testing, the company can deliver increased productivity that competitors can't match.
• 🤝 Customers appreciate the transparency and data-driven decisions that come from scale testing, leading to greater trust in the solutions provided.

Q & A

What is scale testing in the context of the provided transcript?

Scale testing is a protocol that involves creating smaller-scale versions of real-world scenarios to test and validate designs in a cost-effective and time-efficient manner.

How does scale testing benefit customers according to the transcript?

Scale testing allows for quick and cost-effective testing and adjustments, reducing the risk of putting operations at risk and minimizing downtime costs that could run into hundreds of thousands or millions of dollars.

What types of products are typically put through scale testing as mentioned in the transcript?

Products that involve large capital purchases, such as large excavators, shovels, and buckets, are typically put through scale testing.

What are some of the factors considered when setting up a scale pit for testing?

Factors such as bench heights, particle sizes, densities, and material selection are considered to ensure the scale operation matches real-world conditions.

How does the Titan system contribute to the scale testing process?

The Titan system records all sensors on the machine in real time, allowing for the calculation of payload loads and fill energy during testing, which can be viewed on-screen and analyzed later with string gauge data.

What is the importance of avoiding over-customization in scale testing as highlighted in the transcript?

Over-customization can lead to solutions that are too specific and not applicable elsewhere. Scale testing should aim for solutions that solve specific problems but can be broadly applied across various applications.

How does scale testing set the company mentioned in the transcript apart from its competitors?

The company stands out because most competitors lack the ability to test and validate designs as effectively. They may go to market with suboptimal solutions or unverified assumptions, whereas the company optimizes solutions beforehand.

What is the significance of measuring productivity in scale testing as per the transcript?

Measuring productivity in scale testing is crucial because it provides insights into potential improvements and allows the company to deliver enhanced productivity results to customers that others cannot.

How does transparency in scale testing affect customer trust according to the transcript?

Transparency in scale testing, demonstrated by sharing detailed information and data, builds customer trust as it validates the solutions provided before they are implemented in the field.

What is the customer's reaction to the accuracy of scale testing as described in the transcript?

Customers are amazed at the accuracy and similarity of scale testing results to their actual on-site experiences, finding it highly effective and valuable.

Why does the company believe in the solutions brought to the table, as mentioned in the transcript?

The company believes in its solutions because they are backed by rigorous validation through scale testing, ensuring that what is presented to customers is reliable and effective.

Outlines

00:00

🔍 Scale Testing: Optimizing Design Through Miniature Simulations

Scale testing is a method of downsizing real-world scenarios to smaller, more manageable machines for cost-effective and time-efficient design validation. This approach allows for rapid testing and adjustments with minimal risk to operations. Traditionally, design changes could lead to significant manufacturing downtime and costs. Scale testing enables precise manipulation of design elements, quick results, and confidence in field application. It is particularly valuable for innovative or new designs, providing a way to compare multiple options for optimization. Products that undergo scale testing are often large capital purchases like excavators and buckets. The process involves setting up a scaled pit that mimics real-world conditions, including bench heights, particle sizes, densities, and material selection. Machine constraints are then scaled down to match these conditions. Wear, bucket fill, and void detection are assessed using visual metrics, cameras, and real-time sensor data. This data can be analyzed in the office alongside string gauge data for a comprehensive understanding of machine performance during testing. The goal is to find a solution that is not only specific but also broadly applicable across various applications. Competitors often lack this capability, leading to suboptimal or untested market releases. Scale testing allows for pre-market optimization and validation, ensuring that the solutions provided are not only wear-resistant but also productive. Customers appreciate the transparency and data-driven decisions that come with scale testing, often noting the high accuracy and similarity of the testing results to on-site conditions.

Keywords

💡Scale Testing

Scale testing refers to a method of reducing real-world scenarios to smaller, more manageable tests to validate designs and solutions. This approach is cost-effective and time-efficient, allowing for rapid testing and adjustments. In the context of the video, scale testing is used to optimize large capital purchases like excavators and buckets, ensuring that the final solution is the most effective before full-scale implementation. The script mentions that scale testing allows for quick manipulation of machine parts to improve performance and provides the confidence that the results will translate into real-world applications.

💡Cost-Effective

Cost-effectiveness in this video script pertains to the economic advantage of scale testing, where it allows for testing and validation of designs without incurring the high costs associated with full-scale manufacturing or operational changes. The script illustrates this by contrasting the potentially millions of dollars in downtime that could be required for traditional design changes with the relatively lower costs of scale testing.

💡Live Pit

A live pit, as mentioned in the script, is a scaled-down version of the actual working environment where the testing takes place. It is designed to mimic real-world conditions such as bench heights, particle sizes, and material densities. The live pit is crucial for scale testing as it provides a controlled environment to test machine constraints and performance under conditions that closely resemble actual use.

💡Machine Constraints

Machine constraints refer to the limitations or specifications of the machinery being tested, such as wear and bucket fill. In the video's context, understanding and accurately scaling these constraints is essential for ensuring that the testing accurately reflects the performance of the machines in real-world operations. The script discusses how these constraints are scaled down to suit the live pit for testing purposes.

💡Optimized Approach

An optimized approach in the script implies a method or solution that has been fine-tuned to achieve the best possible outcome. Scale testing is highlighted as a way to achieve optimization by allowing for adjustments and improvements to be made in a controlled environment before implementing them on a larger scale. The script emphasizes that the end goal of scale testing is to provide customers with an optimized solution that maximizes efficiency and performance.

💡Downtime

Downtime in the script refers to the period when machinery or operations are halted for maintenance, repairs, or design changes. Traditionally, making changes to machinery like buckets could result in significant downtime, which is costly. Scale testing helps to minimize this downtime by allowing for design validation and improvements in a smaller, controlled setting before full-scale implementation.

💡Sensors and Real-Time Data

The script mentions the use of sensors and real-time data in the scale testing process. Sensors are used to collect data on machine performance, such as payload loads and fill energy, during testing. This real-time data is crucial for understanding the machine's performance and making informed adjustments. The Titan system, as mentioned, allows for the recording and real-time analysis of sensor data, which is vital for optimizing machine performance.

💡Productivity

Productivity in the context of the video refers to the efficiency and output of the machinery being tested. Scale testing aims to enhance productivity by ensuring that the machines are operating at their peak performance. The script highlights that by measuring and optimizing for wear and other factors, scale testing can lead to increased productivity, which is a key benefit for customers.

💡Transparency

Transparency is emphasized in the script as a key aspect of the scale testing process and the relationship with customers. By providing transparent information and data-driven decisions, the company can build trust with its customers. The script suggests that this transparency is a differentiator, as it allows customers to have confidence in the solutions provided and understand the rationale behind the recommendations.

💡Innovative Solutions

Innovative solutions are new and creative approaches to problem-solving. The script mentions that scale testing is particularly valuable when there is something innovative or new that needs to be tested. This could involve trying out multiple options to determine the best solution for optimizing a product or process. The ability to test these innovative solutions in a controlled environment is a significant advantage of scale testing.

Highlights

Scale testing is a protocol for cost-effective and time-efficient validation of designs.

It allows testing in a live pit while providing customer control.

Scale testing optimizes solutions for large capital purchases like large car slips and buckets.

Traditional design changes involve significant downtime and costs, which scale testing mitigates.

The process involves manipulating specific pieces for quick and confident results.

Scale testing is particularly valuable for innovative or new approaches.

It helps determine the best solution among multiple options for optimization.

Understanding the material being tested is crucial for setting up a scale pit.

Real-world conditions like bench heights, particle sizes, and material selection are replicated.

Machine constraints are scaled down to match real-world operations.

Visual metrics and cameras are used for monitoring during scale testing.

The Titan system records sensor data in real time during testing.

Data is analyzed with string gauge data for an informative view of machine performance.

Scale testing avoids over-customization that limits broad application.

It provides results that are broadly applicable across various applications.

Scale testing sets the company apart by allowing thorough testing and validation.

Competitors often go to market with suboptimal solutions without scale testing.

The company can optimize solutions and ensure they deliver the right results pre-market.

Scale testing measures both system wear and productivity.

Customers appreciate the transparency and data-driven decisions from scale testing.

Customers often report that scale testing closely mirrors real-world on-site conditions.

The company's commitment to validated solutions builds customer trust.

Many customers have found significant value in scale testing.

Transcripts

scale testing is a testing protocol that

we use where we scale down real world

scenarios into smaller machines so that

we can test and validate the designs we

come up with uh in a way that's cost

effective and time

efficient it allows us to actually test

them in our live pit to provide the

customer a control but at the same time

the end solution the end solution is the

absolute optimized approach for our

customers it allows you to do a whole

bunch of testing and adjusting quickly

but cost effectively so that you don't

have to put mindsight operations at risk

traditionally if you wanted to make a

bucket design change you know you're

looking at hundreds of thousands maybe

even millions of dollars worth of

downtime in manufacturing fabrication

with scale testing we can manipulate the

exact pieces that we are looking to

improve we can get the results quickly

we can be confident with that and we

know that that translates into the field

it's particularly valuable when there's

something Innovative or new that we're

trying to do or perhaps where there's

three three or four different options

that you might want to figure out which

is the the best solution to optimize

something products that are actually put

through scale testing are are the

products that are really based around

large Capital purchases large car slips

large buckets stuff like

that there's a lot of different ways we

can do scale testing first of all you've

got to understand what it is that you're

digging in and make sure you start by

setting up your scale pit or your scale

operation to match what's happening in

the real world so you're talking about

bench Heights you're talking about

particle sizes densities material

selection all that kind of stuff once

you've got your pit scaled you can then

look at the actual machine constraints

and scale that down to suit and make

sure that you've got the right

parameters scaled correctly with wear

and bucket fill and void detection we

typically use sort of visual metrics or

cameras we've got buckets with viewing

ports we also have a model of our Titan

system on the machine so the Titan

system allows us to record all the

sensors that we have on this system in

real time so not only are we calculating

the payload loads and the fill energy in

real time as we're doing this testing

allowing us to view it on the screen as

we're doing the testing we can also then

take that data back up to the office and

play that in real time in conjunction

with the string gauge data which allows

us to get a really informative view of

what's going on with the machine as it's

digging you can customize too far where

you end up saying you know it suits

something so specifically that you

actually can't use it anywhere else and

that's the danger of not doing scale

testing because you find a specific

start with a specific condition you try

and solve that problem and you create a

whole bunch of others so for us putting

stuff into the scale test situation you

get a result that solves a specific

problem that can be used broadly across

you know all their

applications scale testing sets us apart

because most of our competitors just

don't have the ability to really test

and validate something this way uh

they'll have to go to market either with

something that's suboptimal or something

that they just think is going to work

and even if it does work you still don't

know whether you could improve it

whereas we get the to say let's optimize

it beforehand and make sure that it then

really delivers the right results it's

one thing to measure whether a system

wears but if you can't measure the

productivity you never know what you're

missing so that really gives us the

ability to deliver extra productivity

type results to our customers that

others just can't do when we go down

these paths on optimiz Solutions and

utilizing scale testings customers

normally drop their guard because what

they tend to see is us open up with a

lot of transparent information and data

that's driven to the decision that we

provide so validating that before it

actually gets seen in the field allows

them to have a lot more faith in what is

brought to the table by CR because we

believe in our solutions that we bring

to the table we believe in everything

that we validate to the customer many

customers have got a tremendous amount

of value out of the scale testing but

something that we often hear customers

say is they're amazed at how accurate

and similar the scale testing is to what

they actually do on site it's been

highly effective highly valuable and

yeah we certainly want to do more of

that going

[Music]

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