PRODUCTIVITY PC200-8 at PT Nyalindung, Padalarang, Bandung Regency
12-01-2010
As the leader in excavator technology and design, Komatsu is consistent in providing the best heavy equipment for customers, operators, and working condition. Through UT, as the official distributor, Komatsu will launch the New PC200-8 on January 21st, 2010.
Collaborating with one of its customer in Bandung Regency, UT conducted the trial of KOMTRAX application on PC200-8 for sand mining job. This program aims to assist customer in increasing the performance of their heavy equipment.
Locations of sand mining for construction building are commonly found at river area as well as mountain, such as in Padalarang. Since sand size varies, screening process is needed to be used for building construction. PC200-8 has the important role for loading sand to screen facility.
The Specifications & Application Komatsu Handbook Edition 29 elaborates that bucket capacity of PC200-8 is amounted to 0.93m3, while its cycle time using 90º -180º swing angle is 17-20 seconds and the work efficiency in good working condition is 0.83. With 0.75 bucket fill factor, productivity of PC200-8 will achieve 116 lcm/hour or 103 bcm/hour.
In order to compare with actual conditions in the field UT’s Application Engineering team, in cooperation with customers, has made direct measurements using Data Acquisition Analysis (DAA) software as well as measurement of vessel containment truck to produce the following data:
Table of PC200-8 Joint Survey Productivity Results at sand mining, Padalarang
The above survey results, compared with theoretical calculations, resulting in actual calculations of 23% greater productivity.
Based on the results of UT Team’s survey and analysis results several constraints have been identified, as follows :
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Low productivity time or primary time at about 63%. UT engineering sets the standard of primary time and secondary time excavator at 85% : 15%. That means to achieve excavator optimum productivity, non productive movement should be limited to 15% of overall work time. High secondary time usually occurs when the excavator has to remove waste material from the screening process.
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Limitation of sand material supplied for screening. Often excavator has to wait for dozer or dig the sand material located farther from PC200-8 working range.
With 11 seconds cycle time only, the screening process could not offset the excavator speed because the excavator is often forced to load the sand on top of the screening, while there is a remaining pile of sand from the previous supply. As a results screen efficiency becomes low, which is only 62.3%.
In order help customers improving the PC200-8 performance, UT through Application Engineering Team provides recommendations on the above issues, such as:
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To increase the excavator productive time, the operator should manage the time to dispose the remaining material from screening process. This job should be done during truck shift exchange, not during loading time to the screen. In addition, the area for waste material disposal should be made wider in order to accommodate the possibility if the excavators have to fill larger capacity truck as tronton.
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Excavator for sand materials feeder should be able to work more effectively in supplying sand material to area when its located closer to the excavators for screening. The utilization of bulldozer as equipment to supply sand material should be increased in its intensity.
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Screening process can be done more quickly by using two screens. At the top, screen with larger hole, and at the bottom the screen with expected output. By this method, material loading process into the screening may perform faster and the screening process efficiency can be improved.
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Foreman supervision in the field also a determinant factor for high production results. Without supervision and good management of heavy equipment fleet, it would be impossible for customers to reach the best productivity.
PC200-8 has been equipped with KOMTRAX, whose optimized utilization as one of the advantages of Komatsu products, will improve work efficiency. With KOMTRAX, customers can remotely monitor the unit condition, such as monitoring the work efficiency of PC200-which is operating in the field. In KOMTRAX PC200-8 report, at Padalarang sand mining, customers can obtain Energy Saving Operation Support Report as illustrated in the following picture:
From the data above, customers can find out how long the operator has run to the excavator engine for work and for idle (engine on). The picture above shows that the Actual Working Hours was 477.8 hours out of the total Working Hours of 567.4 hours, which means equal to working efficiency of 84%. Using this facility, field supervisors can alert the operator if work efficiency is considered too low, resulting in lower production.
To learn more about KOMTRAX uses in real time, as well as other information of PC200-8 at Padalarang grit mining. You are welcome to try the KOMTRAX link provided below, using the following user id and password:
https://www-komtrax.komatsu.co.jp/kap/ww/login.aspx
user id : id_ut_guest
password : komtrax
Good Luck!
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