Year XXX n.6 - September 2018
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Sandvik Mason Brothers keep on crushing
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Wirtgen Group Surface miners drive up savings
Spare Parts
A lesson from Volvo CE
Volvo CE explain us the five rules of global parts distribution
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Contents
Year XXX n.6 - September 2018
Sandvik Mason Brothers keep on crushing
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Year XXX n. 6 | September 2018
Wirtgen Group Surface miners drive up savings
Editor in chief Manuela Cortesi manuela.cortesi@scimedia.it Contributors John Melegatti, Marianna Senni, Miriam Spada Administration office Phone: +39 0542 22601 E-mail: info@scimedia.it Subscriptions Italy: € 60,00 - Other countries: € 90,00
News > Short Stories
p. 2
Spare Parts > Volvo Construction Equipment
The five rules of global parts distribution John Melegatti
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Publisher Emanuele Giovannini emanuele.giovannini@scimedia.it
Spare Parts
A lesson from Volvo CE 000_COVER_MT_ENG.indd 1
Volvo CE explain us the five rules of global parts distribution
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At work > Wirtgen Group
At work > Sandvik
Surface miners drive up savings in coal mining Miriam Spada p. 8
Mason Brothers keep on crushing with Sandvik John Melegatti p. 12
News > Short Stories Wacker Neuson
Wacker Neuson reports substantial increase in revenue and profitability New record revenue
Growth across all regions
The Wacker Neuson Group reported a marked rise in revenue and earnings during the first six months of 2018. Revenue for the first half of 2018 rose 8 percent to a new record high of EUR 825 million (H1/17: EUR 764 million). Adjusted for currency effects, this corresponds to an increase of 12 percent. Revenue growth was driven primarily by continued high levels of demand in the construction market and strong performance in the European agricultural sector. Bottlenecks among some suppliers prevented machines from being completed for customer orders and this had a dampening effect. Furthermore, unfavorable currency developments, in particular the US dollar’s weakness against the euro, resulted in negative translation effects.
In Europe, which is the Group’s largest sales market, revenue for the first half of 2018 rose 8 percent to EUR 599 million (H1/17: EUR 556 million). This region’s share of Group revenue remained unchanged at 73 percent. “Our strong performance in this region was fueled by a buoyant construction market, positive development of our Kramer and Weidemann brands in the agricultural sector and growth in our services segment, which includes our maintenance and spare parts business,” explains Martin Lehner, CEO of Wacker Neuson SE. Revenue for the Americas region rose 9 percent to EUR 202 million (H1/17: EUR 185 million). The weak US dollar had a particularly strong impact in this region. When adjusted for currency effects, revenue rose 21 percent. A high level of investment activity among rental chains in North America and strong sales of compact equipment had a positive effect on business. “Our skid steer loaders manufactured in the US are key products in our compact equipment portfolio, helping us to win more market shares in the region with other products such as excavators and dumpers,” adds Lehner. Revenue in Asia-Pacific rose 4 percent to EUR 24 million (H1/17: EUR 23 million). The strong euro also squeezed growth figures here. Adjusted for currency effects, revenue rose 11 percent.
Significant rise in profitability Profit before interest and tax (EBIT) grew by a substantial 28 percent to reach EUR 78 million in the first half year (H1/17: EUR 61 million). This corresponds to an EBIT margin of 9.5 per-
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cent (H1/17: 8.0 percent). The rise in revenue coupled with strict cost control measures and improvements to internal processes had a positive impact here. Increased material prices had a dampening effect, as did material bottlenecks among suppliers, which disrupted workflows at production facilities. Productivity was also affected by ongoing restructuring initiatives across US production plants and the start of production at the new factory in Pinghu, China.
One-off earnings from the sale of a real-estate company held by the Group In June 2018, Wacker Neuson SE sold a real-estate company with an industrial property in Munich-Milbertshofen. The property was no longer required following the construction of a new R&D center for light equipment in Reichertshofen. The sale generated profit before tax of EUR 54.8 million. This aligns with the expectations communicated by the Group in February 2017.
Guidance for 2018 confirmed ”Due to the current healthy situation on international construction and agricultural markets, our most important target markets are intact and our order books are well filled,” continues Martin Lehner. The company has confirmed its guidance for fiscal 2018 and expects revenue to rise by 8 to 11 percent to reach between EUR 1.65 and EUR 1.70 billion (2017: EUR 1.53 billion). The target corridor for the EBIT margin remains at 9.0 to 10.0 percent. Uncertainties remain regarding the challenging situation with suppliers and future exchange rate developments, especially in relation to the US dollar.
Spare Parts > Volvo Construction Equipment
Volvo CE delivers spare parts to all corners of the globe
The five rules of global parts distribution How do you transport one of any 100,000 spare parts across the globe at any given time? Here we look at the intricate choreography Volvo CE has perfected to ensure everything is in the right place at the right time John Melegatti
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The EMEA warehouse of spare parts in Ghent, Belgium
I
f construction machines are the moving hands and feet of a contractor’s operation, then its elaborate distribution network of spare parts is its backbone. For any construction equipment owner, machine uptime is at the core of keeping their business running smoothly. So when a helping hand is needed, Volvo CE steps up to complete the seemingly impossible task of providing all the right parts at the right place at the right time. Jannicke Serneberg, Logistics Director, EMEA, at Volvo CE, says: “Nobody has a crystal ball – you simply cannot know where in the world and when a component might break down. But at Volvo CE, we have created a virtual crystal ball and taken a proactive approach to distribution.” Here we look at the 5 rules to ensure all these moving parts are kept on track.
1. Design High Quality Parts The first step to securing optimum uptime for customers is to ensure parts don’t break down in the first place. By designing extremely high-quality parts that stand the test of time, customers don’t have to worry about their machines failing on them in the middle of the job. Volvo CE test and develop its own parts and products, including the engines, so almost eve-
ry aspect of the machine is manufactured in-house to ensure top quality and easy availability. Access to these quality parts is also made easy, even in the most remote locations. Mobile service stations, containing spare parts and on-site technicians, have been set up on far flung construction sites so that when even the most reliable parts reach their sell-by date, no time is wasted in replacing it.
2. Set Up a Strong Network To handle every potential distribution need, Volvo CE has implemented a strong logistics network with the largest supply of world class spare parts to deliver to time and to budget. The organization oversees an international network of suppliers, parts purchasing, aftermarket purchasing, regional and local market logistics operations, warehouse managers, transport
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Spare Parts > Volvo Construction Equipment
planning, material management and finally dealers and sub-dealers. Phew. Take the EMEA region (Europe, Middle East and Africa) as an example. The region’s storage facilities in Ghent, Belgium, are as large as 16 soccer fields. Each day, 60 trailers and 14 containers are loaded and sent out to up to 550 locations worldwide. With 345,000 spare parts available, there are over 1.2 million order lines handled each year. Mr Torben Volder, IT and logistics manager of the Volvo Entreprenörmaskiner A/S, Denmark, said “For us,
parts availability and the possibility of order and distribution are the most important things. It’s the only way for us to deliver the high service our costumer expects and securer uptime for our customer’s Volvo machines.”
3. Be smart with technology Over time, distribution has become a lot more sophisticated than just physically moving something from point A to point B. So once that network is set up, it needs to be able to handle
The Uptime Center in Eskilstuna, Sweden
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huge amounts of data and communicate that data in the most efficient way possible. Virtually integrating the whole supply chain – and aligning all departments with the same stock management systems – enables Volvo CE to have real-time insights into production times, analyze the quickest transport routes and track each delivery through connected GPS systems. Access to Big Data can help with that virtual crystal ball. Jannicke adds: “We look at the market and machine population, analyze machine utilization trends and make calculated assump-
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tions about what parts might be needed where and when based on all this information.”
4. Prioritize every order Each customer request for a spare part is classed according to need. A first class ‘machine down’ order, where a machine is taken out of action until the part can be replaced, is considered the top priority. In these cases, parts can be delivered in as little as 12 hours. Next in line are second class orders where customers are preparing for a bigger overhaul, followed by discounted classes where customers do not require parts to arrive as soon as the next day. The process of prioritizing every order is not possible without strong channels of communication – both with the customer and with other departments. Every week the logistics team based at Volvo CE’s Uptime Center – based in Eskilstuna, Sweden, for the EMEA region – oversees strategy meetings with warehouse, material management, purchasing, planning and transport teams in order to plan its overall service. This allows distribution centers to more easily plan the comings and goings of parts, reducing costs for everyone involved.
5. P lan low-carbon transportation Anyone involved in logistics is well aware of the environmental challenge of delivering parts to the most remote locations. But for a company like Volvo CE, where sustainability remains one of its core values, it is able to reduce its carbon impact by calling up-
Carl Slotte
President, Volvo CE Sales Region EMEA
on its sprawling network of storage facilities across the world. The company’s huge global footprint means customers do not have to travel far to find local replacement parts. But if longer haul transport is required, Volvo CE will opt for the most low-carbon transportation routes. The world is evolving fast and the demands on distribution are growing every day,” says Jannicke. “But these demands are what push us to be more innovative with the way we work. Distribution has been under the radar in the past but it really is the heart of a business’ operation. After all you don’t call up when you get your parts on time, but you do when you don’t.”◀
INFO The Volvo Group is one of the world’s leading manufacturers of trucks, buses, construction equipment, and marine and industrial engines. The Group also provides complete solutions for financing and service. The Volvo Group, with its headquarters in Gothenburg, employs about 95,000 people, has production facilities in 18 countries and sells its products in more than 190 markets. In 2017, the Volvo Group’s net sales amounted to about SEK 334.7 billion (EUR 34.1 billion). The Volvo Group is a publicly held company. Volvo shares are listed on Nasdaq Stockholm.
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At work > Wirtgen Group
Surface miners drive up savings in coal mining Mine operators for some time now have been increasingly turning to an alternative to conventional rip-and-stack or drill-and-blast coal mining: the use of surface miners. Diverse studies and tests show that surface miners offer considerable advantages in terms of both economic efficiency and the final product Miriam Spada
Using Wirtgen surface miners in the mining process significantly reduces equipment, labor and time requirements as well as overburden volumes. They have a decisive influence on the cost-efficiency of the overall process
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T
he main advantages of Wirtgen surface mining technology include the following:
▶▶ Selective mining ▶▶ Avoidance of blasting ▶▶ Cutting, crushing and loading in a single operation ▶▶ Maximum exploitation of deposits ▶▶ Reduced transport costs Wirtgen supplies surface miners in a variety of performance classes for the selective mining of commodities, such as coal, limestone, bauxite, gypsum, salt and phosphate. In addition to mining, these machines can also carry out routing operations for constructing roads and railway tracks, rehabilitating roadways and installing tunnel floors. The range of applications further includes the precision cutting of ditches and channels as well as surface leveling. In collaboration with RWTH Aachen University, Wirtgen conducted a study in a black coal mine in Queensland, Australia. This article will explore the advantages that surface miners offer in coal mining based on the results of this study.
Case study The 4200 SM surface miner was integrated into an ongoing operation for the selective mining of coal and interburden. Previously defined targets were checked regularly to determine if they were being met. The project score card (Figure 1) illustrates the advantages of using a surface miner in this mine. The production rates of the surface miner were compared with that of the previously used rip-and-stack method over a period of four months based on various performance indicators. The conventional mining system comprises two supersize dozers for ripping and stacking the material and a
super-large wheel loader for loading it to dump trucks with payloads of 130190 t.
Better HSE Compared to the three mining machines used at the mine previously, using a surface miner significantly reduced noise emissions. Mining with the 4200 SM likewise has a positive impact on dust emissions. In contrast to the dozers and wheel loader - all of which generate considerable quantities of dust that impact the work environment - the dust produced by a surface miner is contained in the cutting drum housing. A dust suppression system comprising an integrated water spray system also helps to additionally reduce and bind the dust. An analysis of the two mining methods further demonstrated that fuel consumption is about 79% lower – and therefore also CO2 emissions – with surface miners than when using the conventional method (Figure 2). The lower number machines in use additionally has a positive effect on risk management, because fewer machines mean a reduced risk of accident at the mine. The surface miner’s anti-vibration cabin offers better ergonomics and optimized working conditions for the machine operator. The vibrations generat-
Surface miners from Wirtgen extract commodities in a selective operation, achieving high degrees of purity and maximizing exploitation of the deposits
ed in the 4200 SM were rated as “low” according to Australia’s AS 2670-2001 standard, while the ratings for the conventional systems were higher.
Lower processing costs thanks to reduced fines Coal seams generally are of varying thickness and separated by interburden layers. Precisely separating the various materials is of tremendous importance if coal is to be mined as costefficiently as possible, because it significantly reduces processing costs. Another major cost driver in this regard is the percentage of fines, because they are much more costly to process than coarse material. For the study, a total of 100 samples (30 t each) were analyzed during operation of the surface miner to determine the particle size distribution. Those samples were compared with similar ones taken from the conventional mining equipment and identical mining fields. Significant advantages emerged when working with the surface miner, which produced 14% fewer fines at grain sizes of less than 2 mm compared to the conventional mining system. The portion of fines to be processed dropped by
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At work > Wirtgen Group
22% at grain sizes of less than 1 mm and even by 36% at grain sizes of less than 0.5 mm. Further savings were achieved by significantly reducing the quantity of oversize. For example, only 17% of the material mined by the surface miners had to be crushed compared to 26% for the dozers. The deposit analyzed in the study contains siderite intrusions, particularly at the boundary between seam and interburden. In the conventional process, this frequently led to difficulties, because the siderite intrusions are very hard and therefore difficult to mine. As a result, dozers frequently produce oversized siderite boulders that cause blockages in the crusher. This is not the case when mining with a surface miner. In addition, working with a surface miner reduced coal mining losses and dilution of coal in the mine. This leads to more product, hence increased turnover and even an improved exploitation of the deposit and thus a better stripping ratio. Wirtgen surface miners can load material via stable conveyor systems directly into trucks or dumpers in a single operation. The material can also be deposited in windrows between the crawler tracks or placed alongside the machine
Three tasks in a single operation Wirtgen surface miners can cut, crush and directly load material onto trucks or dumpers in a single operation. This saves time and the additional cost of purchasing machinery and fuel. Working with the 4200 SM in the Australian mine resulted in a 79% reduction in fuel consumption per cubic meter of mined material. Labor costs were reduced by 60% and mining unit costs per ton were reduced by 60% compared to the conventional mining method. The score card clearly demonstrated that - when the entire process chain is taken into consideration - mine operators benefit from tremendous cost reductions when using a surface miner. These reductions are not only a result of easier processing. The smaller number of mining machines and reduced manpower described above and the avoidance of additional costs for transporting and processing waste rock also contribute significantly to the good overall score achieved by the surface miner. Not all benefits that result from the surface miner were part of the conducted study. Additional benefits are described below.
The Australian mine has up to 27, mostly thin, coal seams, meaning it is ideally suited for Wirtgen surface miners
Avoiding blasting means avoiding danger With surface miners, drilling and blasting can be eliminated. In other words, even commodities located in the vicinity of residential areas, public roads or other infrastructure can be effectively mined. It is likewise possible to mine resources located in buffer and safety zones. In most cases, planning and execution of blasting work is associated with considerable effort, high costs and regulatory restrictions. In fact, eliminating drilling and blasting relieves the people responsible of a number of challenges. Mine operators no longer need to spend time obtaining the required permits, hiring certified blast personnel or compiling the associated documentation. Furthermore, getting rid of drilling and blasting has a very positive impact on public opinion, meaning that opencast mining operations can proceed without causing friction in a community. The following are further advantages of eliminating drilling and blasting: â–śâ–ś Enhanced safety at the mine because no explosives need to be stored
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▶▶ No boulder handling necessary ▶▶ Less impact on the environment (vibration, dust and noise) ▶▶ No interruptions for blasting (production delays) ▶▶ Improved slope stability ▶▶ Reduced rockfall ▶▶ Better re-cultivation of embankments The use of a surface miner also has a positive effect on water management at an opencast mine. The cut surfaces are levelled and can be cut at an angle. Drainage is further improved as a result and water seepage into the ground is reduced.
Haulage: more tons per hour The major cost factor in opencast mining is haulage. Mining with Wirtgen surface miners produces level surfac-
Figure 1
es that serve as stable roadways, supporting the rapid transport of material. This increases the transport capacity of the entire truck fleet. Even wear on tires, frame and suspension is reduced thanks to the quality of the roadways, making it possible also to employ standard on-highway trucks.
Surface miners improve quality and cost-efficiency In recent years, Wirtgen has conducted several large-scale field tests on particle size distribution and ROM material degradation. In these studies, coal and sedimentary ore from eight different pits were analyzed to determine their particle size distribution. Some 8,000 t of material were screened to compare the mate-
The Wirtgen 4200 SM surface miner scores high in productivity, safety, targeted grain size and especially cost-efficiency
rial produced by surface miners with that extracted by conventional mining methods. All of the studies illustrate that using Wirtgen surface miners delivers compelling improvements in final product quality, cost-efficiency, environmental protection and safety. In order too fully exploit the surface miners’ profit potential an analysis should be conducted when starting the planning of a mining project.◀
INFO WIRTGEN GmbH Reinhard-Wirtgen-Strasse 2 53578 Windhagen - Germany Phone: +49 (0) 26 45 131 0 www.wirtgen.com
Figure 2
Analysis of the comparative data indicates that use of the Wirtgen 4200 SM surface miner reduces fuel consumption by 79%
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At work > Sandvik
Mason Brothers keep on crushing with Sandvik Pembrokeshire based Mason Brothers Quarry Products has a longstanding relationship with Sandvik which goes back to the 1990s. The company now produces in excess of 100,000 tons of high quality aggregate from its Rhyndaston quarry, with a mobile crushing, screening and scalping train from Sandvik John Melegatti
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M
ason Brothers Quarry Products is family run business which has carved out a niche in supplying sand and aggregates throughout Pembrokeshire, Ceredigion and Carmarthenshire for over 25 years. Due to high demand, many of its varied products are also supplied further afield, with the company priding itself on producing and supplying
products of the highest quality at competitive prices, delivered where and when its customers require them. “We run six tipper trucks out of the quarry and now produce over 100,000t of mixed aggregates,� stated company Managing director Alun Mason. The wide range of products produced at the quarry ranges from type 1 sub base to ornamental and building stone. The company also supplies a range of
other products including volumetric concrete, concrete blocks, portable gabion baskets, drainage pipe, and is able to deliver materials both loose or bagged dependent on customer requirements. As well as its flag ship operation located at Rhyndaston Quarry, Haverfordwest, the company also works out of other quarries, including its new shale quarry which is also located in Haverfordwest.
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At work > Sandvik
Demanding rock Most of Mason Brothers’ material is produced at its Rhyndaston quarry. “It’s (the rock at the quarry) a metamorphic granite, with its actual name being Royal Lite Hornfeldt. It breaks reasonably easy, but it is quite abrasive which makes it hard wearing on any equipment we use,” explains Alun, who continues: “This means we try and sort out equipment that is going to do what
we want, and give us the tonnages that we require, but at the same time keep our costs to a minimum.” A key part of the production process at the Rhyndaston quarry is Mason Brothers’ crushing, screening and scalping train supplied by Sandvik Mobiles. This comprises of a QA451 triple deck Doublescreen, QH331 cone with hanging screen, and currently, a QE341 scalper with finger deck.
The highly productive and efficient nature of the set-up is explained by Alun: “Two boys there run the complete quarry. They primary crush at face and then scalp off the material. We produce a 1-4 inch (25mm-100mm) cone feed from the face which we then stockpile at the rear of the cone crusher. This is then moved across the quarry with an excavator loading the cone for secondary crushing. This set-up enables the running of the entire quarry with just two men.”
Cone crushing developments “They’re always developing and improving things,” says Alun of one of Sandvik’s latest developments which is proving to be essential for his quarrying operation. The QH331 cone crusher with hanging screen was launched at Hillhead in 2016, and its features have proved to be particularly of benefit to Mason Brothers. “Obviously the hanging screen has been a big improvement for us. It’s efficient; we don’t re-circ a lot with it as we tend to try and use all the products
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Sandvik Group Sandvik is a high-tech and global engineering group offering products and services that enhance customer productivity, profitability and safety. We hold world-leading positions in selected areas – tools and tooling systems for metal cutting; equipment and tools, service and technical solutions for the mining and construction industries; products in advanced stainless steels and special alloys as well as products for industrial heating. In 2017, the Group had approximately 43,000 employees and sales of 91 billion SEK in more than 150 countries within continuing operations.
Sandvik Mining and Rock Technology Sandvik Mining and Rock Technology is a business area within the Sandvik Group and a global leading supplier of equipment and tools, service and technical solutions for the mining and construction industries. Application areas include rock drilling, rock cutting, crushing and screening, loading and hauling, tunneling, quarrying and breaking and demolition. In 2017, sales were approximately 37 billion SEK with about 15,000 employees in continuing operations.
Alun Mason
Managing director
the machine produces. Another good thing is that you haven’t got crusher backing to leave ‘cure’. We change between ‘matt’ and ‘concave’ (on the cone) quite regularly, so we can just change and get on with a day’s work.” The QH331 draws heavily on Sandvik’s expertise in cone crusher technology, which as Alun explains has been put to good effect. “We try to keep the shape (of the end product) which is something the cone has enabled us to do. We only primary and secondary crush, we don’t tertiary crush at all, so we have to get that shape right in two stages.”
Long standing relationship Mason Brothers has been using mobile crushing and screening equipment from the Sandvik range for nearly as long as it has been producing aggregates. “We’ve a long, long relationship right back to the Extec days (Extec was acquired by Sandvik in 2007). They’ve always pulled us out and kept us going.” Alun further explains how this excellent relationship between the two companies helps maximize the production and effective use of the equipment. “We are a long way from Sandvik. They do come out as quickly as possible (if equipment requires services, parts or in the rare event of a breakdown) but they also provide good advice over the telephone so we can try a lot of things ourselves without the need to send a service engineer.” Alun Mason’s experience of Sandvik and its mobile crushing and screening equipment is still highly positive after many years working together. “I’d have no problems in recommending Sandvik to anybody. We’ve got a good relationship with them and they’ve looked after us over the years. Well, obviously, we wouldn’t have spent the money with them if weren’t happy with product, and happy with the company.”◀
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