Special Report
Transcription
Special Report
SUMMER 2009 Why is this man smiling? See page 18. MAXIMIZE UPTIME Special Report Finning boasts new and revamped services to keep you up and running Take Command Expose your machine's secret life Placid Lake One B.C. family business faces the downturn with serenity Power Points Planned maintenance readies backup generators www.finning.ca ! DO IT our tY Protec Train Power A FINNING (CANADA) PUBLICATION Non-deliverable mail should be directed to: 10259 105 Street, Edmonton, AB T5J 1E3 Canadian Publications Mail Product Agreement #40020055 Unrivalled Product Support We’ve expanded our service infrastructure to ensure you receive the best service in the business. With our investment in the Centre of Excellence facility, located centrally in Red Deer, Alberta, we have optimized our new equipment preparation process, resulting in improved shop capacity at all 50 service branch locations throughout B.C., Alberta, Yukon and Northwest Territories. This increased shop capacity means reduced downtime and quicker turn-around from shop to field. At Finning, we have the people, experience and capacity to make sure your equipment is in top condition, ready to support your business. Contact your local Finning representative for more details. 1-888-finning | finning.ca (346-6464) uptime issue Summer 09 Contents 28 21 Columns & Departments 4 Finning Focus T&T’s new design: How do you like us now? 5 6 On the Cover Andre Lavallee of Alta-Fab Structures Photograph: Kelly Redinger Features 12 Radical Upgrade 18 Find out what's on the horizon for Finning’s fluid analysis program 18 Built to Last Regular maintenance can increase the lifespan of your yellow iron 21 Don’t Fight the Power Finning is minding backup generators in the Lower Mainland 24 Placid Lake A sibling team keeps business running smoothly 26 Keep It Up (and Running) 17 www.finning.ca A new Finning program swaps out engines needing overhaul in a flash 28 Meeting the Challenge Sparwood Mine Rescue Competition Letters Finning friends speak Groundbreaker Refurbish My Ride; The Clipper Project; Track your iron; Gotta get GET; D series cool facts; Dredger with the heart of a Cat PLUS! Essayons, by the numbers 11 Safety First Great safety programs reward top practitioners 14 Operators’ Tips How to protect your power train 15 Managers’ Tips Is your shop floor efficient? 16 Tech Spotlight A fluid solution 17 Equipment Spotlight Attachments turn one tool into many 30 Yesterday/Today Cat faced the last recession by branching into pavers 31 Portrait Bob Fritchey, 36 years with Finning and still going strong 32 Yellow Iron New products and services from Finning 33 Bill’s Business Bill tries some R&R, only to find a worksite at the campsite 34 Count on Us tracks & treads Summer 2009 32 How Do You Like Us Now? We decided to shake things up a little with a fresh, new look; tell us what you think by Jen Janzen associate editor Welcome to the new improved Tracks & Treads! We’ve done some tweaking to our story lineup and given our appearance a bit of a facelift, stopping just short of infusing the magazine with natural goodness from the rainforest. Our stories are snappier and speak directly to you and your business. The result? In our opinion, a fresher, livelier information source for iron enthusiasts. What do you think? Let me know at [email protected]. This issue also represents my first contributions to T&T – it’s nice to meet you. In this issue, our theme focuses on uptime: how owneroperators are getting more of it and what you can do to increase your own share of it. In some ways, uptime boils down to a simple concept: preventive maintenance. Proper lubricants, filtration, oil sampling and overall condition monitoring can make the difference between uptime and downtime. If you perform diligent maintenance, you should be rewarded with more hours of use. Think of it as scheduled downtime that increases your overall uptime. Another bonus is that by performing regular preventive maintenance, you catch problems before they become catastrophic, especially when your efforts are supported by Finning’s various product support programs. And tracks & treads Summer 2009 catching trouble right before it rears its head means you decrease the risk of pulling your machine off duty too early. Finning (Canada)’s product support marketing manager Stu McLeod agrees that finding the optimal repair before failure date can be difficult. “It’s the Holy Grail of all maintenance programs,” he said, “and the fulfillment of a machine owner’s ultimate goal of maximizing component life.” But hitting this elusive target does not mean scheduling repair before it’s necessary. Every owneroperator wants to keep a machine performing at its top capacity, but replacing components before they’ve expired – when you could have gotten many more hours of use out of them – ends up costing your business more money. Ultimately, Stu says, a machine is eventually going to need repair whether it’s had a strict preventive maintenance regimen or not. But preventive maintenance, along with a healthy dose of advice from Finning’s seasoned product support pros, will extend the life of your machine, maximizing your uptime by helping you make sure you aren’t shutting it down too late – or too early. www.finning.ca sUMMER 2009 Volume 49, No. 2 Publisher Ruth Kelly [email protected] associate Publisher Daska Davis Executive Editor Jeff Howard [email protected] Associate editor Jen Janzen [email protected] Editor Mifi Purvis COPY CHIEF Kim Tannas Editorial Advisors Danna Beatty, Michelle Loewen, Patrick King art director Charles Burke [email protected] ASSISTANT ART DIRECTOR Rodrigo López Orozco Production COORDINATOR Betty-Lou Smith circulation coordinator Andrea Cruickshank [email protected] Advertising representative Anita McGillis [email protected] Contributing Writers Robin Brunet, David DiCenzo, Katherine Fawcett, Keith Haddock, Noémi LoPinto, Lindsey Norris, Rick Overwater, Lisa Ricciotti, Jesse Semko, Jim Stirling Contributing PHOTOGRAPHERS and illustrators Jody Crawford, Scott Dutton, Ricardo Alberto Leiva, Darren Nisbet, Heff O’Reilley, Kelly Redinger, Chip Zdarsky Tracks & Treads is published to provide its readers with relevant business, technology, product and service information in a lively and engaging manner. Tracks & Treads is published for Finning (Canada) by Venture Publishing Inc. 10259-105 Street Edmonton, Alberta T5J 1E3 Phone: 780-990-0839 Fax: 780-425-4921 NOT FINNISH YET: It was with keen interest that I found the picture and caption “Log Day Afternoon” in the fall 2008 issue of Tracks & Treads. In my younger years, I often heard the name “Tomsum EE-Larky.” Both my grandfathers, Olaf and Hugo, were Finnish and both had worked for Thomsen and Clark. Like many new immigrants to Canada, they struggled with English. Both grandfathers have long since passed away. I remember some of their logging stories and I know they worked for more than one outfit. I asked my father if Olaf and Hugo had talked much about Thomsen and Clark to him. Dad could not shed any new light on the situation, but he called up a family friend who could, Leonard Tournquist. His father (also Finnish) worked for Thomsen and Clark. Leonard thinks Thomsen and Clark had been logging near Harrison Lake. He also said there was a book called Harrison Lake Challenge that might have information about Thomsen and Clark. I’d appreciate if you could forward to me any information that you might find on Thomsen and Clark. Doug Vitick, Mildred Lake, Alberta DETECTIVE: I am writing to let you know that I am familiar with the surroundings in the photo on page 42 of the fall 2008 issue. It was taken at an area near Hunt Creek, on Vancouver Island, on a Thompson Clark spur line off of the Horne Lake line. There were two of these machines: Caterpillar tractor and hoister arch. This was approximately 1935. I very much enjoy my T&T subscription. D.S. McMillan THUMBS UP: I used to live in Edmonton and work for Finning. I have been retired for eight years now. When I write that, I wonder where the time has gone. Have just finished thumbing through the latest issue of T&T spring ’09 and had to write and congratulate you and the rest of the T&T staff on what has become a high-quality publication. I read every issue and have been meaning to write for some time. The last few years, with the introduction of “Bill’s Business,” has really seen the magazine shine. Good job. Dave Floyd, Vancouver, B.C. Tell us what you think Tracks & Treads would love to hear from you. Tell us what you think of the magazine’s stories, columns and look, so that we can improve it and make it a more interesting read. Send your comments to executive editor Jeff Howard by email at [email protected] or the old-fashioned way to: Jeff Howard, Tracks & Treads, Finning (Canada), 16830 – 107 Avenue, Edmonton, Alberta T5P 4C3 Contents © 2009 by Finning (Canada) No part of this publication should be reproduced without written permission. www.finning.ca www.finning.ca tracks & treads Summer 2009 32 by david dicenzo, Jeff Howard and Jen Janzen “Get me eight engines, stat!” The US Army Corps of Engineers helps keep shipping channels open on the West Coast of the USA by operating two hopper dredges. The larger of those two dredges, the Portland-based Essayons, recently had eight state-of-the-art Cat marine engines installed which, in dredge parlance, is a heart transplant for the monster vessel. “The new engines have greatly improved our operational efficiency,” said Captain Essayons By the Numbers James Holcroft, in charge of the Essayons for six years. “With the old engines, when dredging upstream and going against a strong current, we barely had enough power to maintain forward motion. With the new Caterpillar engines, we have an extra 2,000 hp enabling us to get the job done, even under difficult conditions.” The length of the Essayons, in metres. 106.7 4 The number of Cat C280-12 main engines used in the Essayons‘ “heart transplant.” 1982 0 The number of kilowatts produced by the eight new Cat marine engines. The number of medical doctors required. 15,000 24 The number of crew members on the Essayons. The number of Cat 3512C generator sets installed. 3 40 The number of Cat C18 emergency gen sets. tracks & treads Summer 2009 The year the Essayons was built by Bath Iron Works in Bath, Maine. The weight, in tons, of the four C280-12s alone. 1 www.finning.ca Connected Fleet Refurbish My Ride As one of the richest people on the planet, billionaire philanthropist Dennis Washington doesn’t scrimp on quality. The Spokane, Washington native and owner of a consortium known as Washington Companies is an avid yachtsman. When he needed to power up a ride he’s refurbishing in North Vancouver, his people got in touch with the Finning branch in Richmond. A Caterpillar C9 generator set will provide some of the juice for Washington’s Attessa IV, which will be fully refurbished by the summer of 2010. The fully electronic, 250KW C9 comes in at a cost of about $95,000 (US). That might seem steep to most folks but, as a regular fixture on the Forbes list of really rich people, Washington can swing it. www.finning.ca New Caterpillar technology is helping to provide a world-class solution to fleet management for pipeline contractors. And PipeLine Machinery International, partly owned by Finning, is the Cat dealer providing this solution to its pipeline customers. Approximately 500 machines in PLM’s rental fleet have been activated on EquipmentManager and Product Link systems, two remote asset management solutions developed by Caterpillar. Here’s what those solutions look like: EquipmentManagerTM • A secure, web-based software application • Uses key indicators such as hours, location and diagnostic codes • Combines with powerful tools such as map- ping, maintenance scheduling and troubleshoot- ing instructions to quickly sort data and identify what items need attention Product Link • Hardware that uses satellite technology to enable information to flow between onboard systems and the web-based EquipmentManager • The remote management system provides basic level readings, including the location of machines and hourly readings • Additional levels include time fencing and geo- fencing (meaning machines shut down outside authorized operating times or geographic areas), diagnostic code alerts and fuel level alerts Did you know? PLM can do an advanced search on EquipmentManager, identifying all machines within a 160-kilometre radius that might require scheduled maintenance in the next two weeks. “It helps all of us and goes a long way to making a cohesive team of the customer (pipeline contractor), the supplier (PLM) and the service provider (Finning or other local dealers who cover the project territory),” said Lindley Imeson, PLM’s equipment operations manager. “This is what we were aiming for when PLM was conceived – a better Caterpillar solution for the pipeline construction industry.” tracks & treads Summer 2009 32 Gotta Get GET As a Finning customer, you put a lot of thought into buying a new machine, studying fuel efficiency, productivity and cost per hour to run. But if you’re working your machine without dressing it up, you’re not getting the most out of your investment. Ground engaging tools (GET) are commonly referred to as "sacrificial iron." That’s because they help protect expensive components by taking the wear for them. Using the right GET for the application also helps maximize productivity. The result? A machine that’s always working at its peak. When old GET wears out, it’s simply replaced with new GET. “Cat GET is designed to work with Cat machines,” says Dave Zesko, Finning’s product manager of wear products. He notes that designing GET is more than “fitting a cavity.” “Cat does a lot of research on the development of the machine,” he explains. “It looks at the way to build a bucket to make sure the machine is getting its highest productivity, and designs GET to enhance the machine’s performance.” A machine is a big investment, Zesko adds. “If you don’t protect it, it will cost more money in downtime and repair costs. That’s why you need to dress it up properly the first time.” “That's why they call GET ‘sacrificial iron.’” – Dave Zesko tracks & treads Summer 2009 Q. How do ground engaging tools wear? A. According to Dave Weiss, staff metallurgical engineer for Caterpillar’s Research Department, the two modes of wear are scratching (low stress abrasion that GET encounter most) and gouging (caused by heavy impacts or blows to a surface). Metal must be very hard to resist scratching, though the same does not apply to gouging. Metal that is too hard will be brittle on impact, so it must be softer, yet still strong. The Clipper Project A new pipeline, extending through three provinces will help distribute Alberta’s petroleum products. The complex Enbridge Alberta Clipper Project, which began in the summer of 2008, will eventually have a 36-inch pipeline running from the Camrose, Alberta area all the way to Gretna, Manitoba, a town just north of the U.S. border, and connecting with the Enbridge Southern Access Pipeline in the US. Contractor WillbrosMidwest is in charge of the 170 kilometres of pipe in the Alberta stretch. It’s tough work, but with a wide array of yellow iron on the job, the project is moving along. Finning supplied much of the traditional iron, including D8 and D6 dozers, 330 and 345 excavators. PipeLine Machinery International, partly owned by Finning, provided some traditional pieces and all of the pipelayers – 572s, 583s and 587s – used on the project. According to PipeLine Machinery’s equipment services coordinator, John Bilawka, there is about 75 kilometres of cleanup remaining in Alberta, to be completed by October. www.finning.ca D Series Uncovered Caterpillar’s D series line of excavators sets the bar higher for heavy diggers. New safety features, comfort and improved efficiency mean that your business won’t be without one for long. Go ahead, kick a track: cost reducer: Caterpillar-exclusive, ACERT Technology lowers operating cost without sacrificing performance or durability. It’s less polluting, and harmful sulfur, soot, heat and moisture are not reintroduced into the engine. Efficiency boost: The D series has eight to 12 per cent more horsepower than previous iron, meaning better performance and productivity. Hot seat: An air suspended heated seat helps operators manage long workdays comfortably. May keep “mature” operators on the job longer. Comfortably safe: Improved air flow for heat, A/C and ventilation makes for safer operation through less operator fatigue and better visibility. A joy to run: The D series has direct joystick response, faster combined movement, easy levelling ability and lower lever effort. lift and dig: Higher hydraulic pressures mean more lifting capacity, drawbar pull, and stick and digging force. Not camera shy: Full color, graphic and camera-ready if a rear camera is installed. reminder: Maintenance intervals can be programmed and the machine will warn you when services are required. It monitors its own prestart fluid levels, filters, water separators and temperature. www.finning.ca Talking iron: It can speak 27 languages to meet the needs of a diverse workforce. Communication is in text, not arcane codes. Power Levels: Set power at high, medium or economy, as needed by the task, reducing fuel consumption to lower operating costs and negative environmental impact. I Spy: Product Link and Asset Watch tell you where your machines are and how long they’ve been operating – you don’t have to leave the office. tracks & treads Summer 2009 32 A New Vocation Finning improves its service promise You could say the engines were so popular Cat decided to build the trucks to go with them. After several months of percolating in the rumour mill, the news is official: Caterpillar is entering the vocational truck business. Vocational, or severe service, trucks are certified for highway or off-road travel to support construction, mining, waste management and logging. Cat and heavy-duty truck manufacturer Navistar will work together to produce Cat-branded vocational trucks in North America. The initiative comes as a response to other manufacturers pursuing vertically integrated drivelines – making and installing their own engines to be placed inside their own trucks. The initiative gives Caterpillar the ability to design trucks tailored to the needs of customers, taking advantage of the legendary support capabilities of dealers such as Finning. Vocational vehicles are the core of the Caterpillar market and Cat hopes to leverage Navistar’s scale and history in the on-highway truck business. The two companies have separate North American and global strategies. In North America, Cat and Navistar will create a new design for vocational trucks. Overseas, Navistar trucks will be Cat-branded and distributed with emphasis on Africa, China and Australia. The first Cat Navistar truck will be introduced next year. 10 tracks & treads Summer 2009 When you contact Finning for service, you have some basic needs. That’s why Finning, throughout its 76-year history, continually strives to improve its serve. In addition to the recent move to add service capacity at branches throughout Western Canada, thanks to the addition of its massive Red Deer new equipment prep and overhaul facility, Finning is refreshing its Customer Service Commitment. Long the backbone of its service offering, Finning’s Customer Service Commitment is designed to address your most pressing concerns – “Will I get my machine repaired on time? Will there be any surprises in my invoice? And what happens if my machine fails again?” “The Customer Service Commitment takes care of these three most basic customer issues,” explains Ken Nordstrom, general manager of Finning West Edmonton location. “And this year we’re enhancing our commitment to customers – instead of six months no-cost warranty repairs on any service work we perform, they’ll now receive 12 months. That adds a lot of peace of mind.” There are other improvements, including money in your pocket, should your Finning service team miss a promised completion date. “That’s right – we’re accountable to our customers,” says Nordstrom. “We’ll issue an account credit or a cheque to the customer to a maximum payout of 20 per cent of the total repair price when we don’t meet a promised completion date.” Along with the improvements in the Customer Service Commitment policy, Nordstrom says customers should notice a difference in the service they receive at Finning branches. “We want to make sure we ask the right questions up front so customers get exactly what they need. And as repairs proceed, if we find that additional repairs are needed, we will discuss these with you and get your authorization before proceeding.” In a classic win-win, Finning customers are already benefitting. And many more are making the decision to put Finning’s Customer Service Commitment to the test. story By Rick Overwater Its Own Reward Focusing on the positive with a recognition program can yield results Water might not seem that dangerous. But when you’re blasting it out at 40,000 psi, it’s a different story. “You can cut a car in half,” says Marilee Rainville, director of Health and Safety resources at the Calgary office of CEDA International, which provides specialized industrial maintenance to oil and gas and other industrial clients. “We regularly use high pressure water to cut holes in tanks or cut the tops of vessels off.” The potential for injury is significant, and this is just one of the many hazards employees of CEDA’s six subsidiary companies deal with in the course of providing industrial maintenance and turnaround services. Rainville says it became obvious that protecting employees required an above-average safety management system. And a particularly effective component of that system has been the awards program. “It’s easy to fall into the trap of an always-punitive kind of system, where incidents happen and someone is disciplined,” says Rainville. “But there’s the other side – where you recognize and promote good performance.” Indeed, when it comes to keeping employees interested in health and safety, an awards component can be an important piece of an effective safety program, says Rose Ann McGinty, an effective practices specialist for the Occupational Health and Safety branch of Alberta Employment and Immigration. “Awards are a nice carrot to help employers get staff interested in health and safety,” she says. “But an awards program isn’t going to fix a bad health and safety system.” McGinty says that if a safety program is not effective, some employers mistakenly create an awards component as a Band-Aid solution. Recognizing safety efforts is important but, first, you must have the eight fundamentals of a good program up and running. You need leadership and organizational commitment. Then you need systems for hazard identification, hazard control, workplace inspections, orientation and training, and emergency response planning. The next components are investigation and, finally, administration, which encompasses auditing and reporting. “Then you can look at those and say ‘What areas do we need to focus on?’’’ says McGinty. “Step one is ‘What do you reward?’ and step two is ‘How do you reward it?’” Careful forethought about how management should reward employees was vital for CEDA. “I would definitely do an employee perception survey on the subject,” says Rainville. The initial idea of rewarding teams was not popular; CEDA employees wanted a program recogniz- www.finning.ca ing individuals. From there, safety leaders developed a system that awarded points for each hour worked without incident. But both Rainville and McGinty stress that rewarding someone simply for not getting hurt is not enough. Instead, rewards should encourage proactive thinking. CEDA awarded points at a higher rate to recognize efforts such as attending safety meetings and workshops. Focusing on such preventive activities helps minimize perceived unfairness in the program, says McGinty. The last thing you want is the guys on the shop floor grumbling about the office workers, who are less likely to be exposed to injury-inducing hazards. And rewarding all individuals for their efforts, as CEDA does, is just as important. “As far as perceived fairness goes, smaller gifts to everyone who deserves it are much better than the one in 100 chance of getting something big and glamorous,” McGinty adds. “You don’t want your program to become about competition as opposed to acknowledgement.” At CEDA, employees cash in their points when they’ve accumulated enough to “buy” one of the many things offered in a special catalogue. They don’t get useless certificates or discounts on company merchandise, either. They get items that the average consumer actually wants, such as mountain bikes, iPods, fish finders and more. The Workers’ Compensation Board rebates that many firms get for good safety performance initially funded their prize purchases. It has worked well for CEDA employees and Rainville is pleased with the uptake of the safety message, citing better safety meeting attendance and a lower number of incidents as just two indicators that they’re on the right track. “We’re glad we did it the way we did because it creates an awful lot of discussion, which keeps the program alive,” she says. “They love it and pay great attention to it. I know that because of all the emails and questions I get at award time.” tracks & treads Summer 2009 32 11 Take Command By Jeff Howard, with files from Lindsey Norris and Lisa Ricciotti New software and lab tests help reveal your machine’s secret life Find Out More! For more information on Finning fluid analysis, contact your Finning representative or call our fluid sampling experts Katrina Ostrikoff (604) 881-2959 or Jody Exell (780) 443-7231. 12 tracks & treads No one gets closer to understanding hidden equipment mysteries than the oftenunsung fluid analysis interpreters. Whether it’s copper or chromium, sulphur or silicon, oxidation or nitration, these heavy equipment scientists can pinpoint potential problems that might otherwise shorten your component’s lifespan. So it’s wise to get their advice early. It can mean the difference between a simple tune up or a major repair and unwanted downtime. And, in some cases, they’ll even be able to tell you if Rusty, your new operator, is riding the brakes a little too hard. For 30 years, Finning’s fluid analysis team, which is affiliated with 147 Caterpillar fluid sampling labs worldwide, has been helping keep Cat equipment in the field and out of the shop. And this fall, Finning labs based in Surrey and Edmonton will take a big step forward when they unveil a new lab management system – Equipment Commander – a web-based software tool that promises to significantly improve your fluid sampling and reporting experience. “This will be a serious upgrade to our system,” says Katrina Ostrikoff, manager, fluid analysis sales, Finning (Canada). “Combined with our thorough understanding of component metallurgy and knowledgeable interpreters, we’ll be able to provide customers with a whole new range of fluid analysis services. I’d ask customers to give us a try this fall.” Ostrikoff says the new system will offer a range of advantages for customers looking for a reliable and in-depth sampling service. The system makes sample reports and interpretive comments available online, giving customers access to their information from anywhere, at anytime. Also, Equipment Commander can send sample notifications how you like them – via email, instant messaging, fax or snail mail. “The program is user-friendly and there is no Summer 2009 Analyze This Last year Finning (Canada) scrutinized more than 240,000 fluid samples, analyzing oil, coolant and fuel at its two labs in Surrey and Edmonton. Surrey averages 275 samples per day; Edmonton about 600 daily. Samples split equally between Cat and non-Cat equipment of all types, both mobile and stationary. installed software,” adds Ostrikoff, “so little training will be required.” The system offers other advantages. Equipment Commander can print labels that include barcodes to speed sample registration. And it keeps all user data in one place, including historical information, fuel and lubricant consumption reports, registration details, images and information about components’ estimated remaining life. “The tool’s ability to forecast means you’ll know when the next samples are due,” explains Jody Exell, fluid analysis manager in Edmonton. “This will keep our customers up-to-date with those all-important warranty requirements.” What won’t change at Finning’s labs in Surrey and Edmonton is hands-on interpretation of customer fluid samples. Contrary to other labs that depend on machine analysis of samples, Finning continues to provide a greater degree of precision and know-how: an experienced oil lab interpreter reviews your sample results. www.finning.ca High-tech Avoids High Costs System Sampler Are you familiar with the science behind fluid sampling? Follow a sample through the works and find out what it tells about your iron. Say you have a 430E backhoe loader. You’ll need samples from all of its major oillubricated systems – including the engine, transmission, hydraulic system and final drives. Pre-register each sample online, then courier or drop off the samples at your local Finning branch or the Edmonton or Surrey lab. At the lab, a technician – perhaps Greg Eyre, lab technician/interpreter in Surrey – will prepare the samples from your 430E for analysis. First, he looks for such things as excessive water, which can combine with sulphur in an oil to form sulphuric acid. www.finning.ca Water can also rust bare metal surfaces inside the compartment which can lead to engine failure. Various lab tests determine such things as oil viscosity, oil condition, contamination (such as water, fuel, glycol, dirt) and particle counts. A high particulate count may mean that excess dirt has entered the system. “This can happen in various ways,” says Katrina Ostrikoff. “It could be during a maintenance procedure, taking of the oil sample or a seal may be broken.” The wear rate analysis will help you plot how quickly oillubricated components are wearing out. It iden- tifies certain elements in the sample. For example, higher levels of iron and chrome may indicate cylinder liner/ piston ring wear. But since a small amount of wear is expected, the tests look for abnormal patterns. Finning’s new system will produce a report that compares the new sample with five previous samples. If elements suddenly spike, there may be a problem. Interpreters then use the technical lab document to compile a more user-friendly report that groups items according to whether they are a contaminant, a wear element, a physical test, a fluid characteristic, an oil condition or a particle analysis. “The new technology will enable us to provide a report," Ostrikoff says, "that displays how long it took your sample to reach the lab, your warranty expiry date plus other new features.” About 24 hours after the lab receives the sample, you get an email (or a fax or letter) that directs you to online results. Busy day? You can select to see only the results that indicate potential problems. Using the new software you can also log on and manage your component life, graph, upload images, send emails to key people with details about the sample, record actions taken plus many more helpful features. When a 797 mining truck represents a $5-million investment, it pays to catch a small problem before it becomes a $300,000 engine-repair bill. Katrina Ostrikoff, Finning (Canada)’s manager of fluid analysis sales, explains some of the high-tech lab tests. Oil, she says, is “like a Rolaids for equipment, helping dilute acid buildup from the heat caused as a unit works.” Eventually the Rolaids effect wears out as oil breaks down and needs to be replaced. Tests like the Total Base Number (TBN) and Total Acid Number (TAN) measure the alkalinity or acidity of an oil sample, showing when it needs to be dumped. The Karl Fischer Water (KFW) test measures the exact percentage of moisture in oil, very important since even tiny amounts interfere with oil’s protective abilities, especially for stationary and hydraulic equipment. tracks & treads Summer 2009 32 13 operators Notes From the Driver's Seat By Lindsey Norris The best maintenance program won’t help your power train if the guy in the driver’s seat doesn’t have the right know-how It goes without saying that you want your equipment to last as long as possible, and to stay active on site, not idle in the shop. It’s why you may forget a niece’s birthday, but you’ll never forget an oil change. But anyone who sits at the controls of one of your machines can undo your hard work if they don’t operate it properly. Here are a few things your operators can do to keep your Cat’s power train in top form. Warm up. Especially in winter, but no matter the temperature, the engine, transmission and hydraulics need to warm up at an idle. Finning's Niles Wheeler, a Catcertified instructor, says this applies to every machine. “So, if it’s an excavator, you have to warm up the engine. Then move the bucket, then stick, then boom,” Wheeler says. “It pumps warmer hydraulics through the system so that you aren’t running cold oil.” Keep your cool. “Heat is your enemy,” says Wheeler. Regardless of what machine you’re operating and what job it’s performing, don’t let it overheat. For example, in a loaded haul truck hauling downhill, don't use high gear. This heats up the braking system causing brakes to fade and wear. Certain specialized operations also generate a lot of heat. For instance, when you're filling a loader bucket and it stays too long in the bank or is positioned incorrectly, the hydraulics overheat, stressing valves and seals. Instead, penetrate the bank in first gear, raise the bucket (giving traction to front tires) then give a steady lift and curl to the bucket to fill it. This should take about 15 seconds and – done correctly – will keep the machine cooler. Come to a complete stop. “With the exception of loaders, you must come to a complete stop before you change direction,” Wheeler says. It’s so important that some machines now give a warning if the operator tries to change direction at higher than two miles an hour. Don’t guess on gears. “The biggest mistake most operators make is they look at a ramp and say, ‘I can go down there in fifth gear,’ and they end up heating the brakes. Start with a lower gear. If the brakes hold and no heat is involved, we can go up one gear,” Wheeler says. “It’s why training is your Number One when it comes to machine operation. Have the best trained operators you can get.” Trust the operators. So the operators on site are trained and experienced, have read their machine’s manual and know their Cat better than they know their own reflection. But not everyone does, so your Cat may still end up doing jobs it shouldn’t. “Sometimes the supervision really drives what happens, and if the supervisors don’t have training, it means they may push their operators to do things they shouldn’t be doing,” Wheeler says. One of the problems he often sees is graders – which are meant to build and maintain roads – being used for site cleanup. But there are a host of considerations that go into proper grader use, such as appropriate speed and blade angle, and they shouldn’t be used to move miscellaneous material. Don’t get stuck in a maintenance rut. Regular maintenance is a must for the life of any power train, but various conditions may increase the pace of your schedule. Operators should pay attention to local conditions, such as dust, for example, which necessitates more frequent filter changes. 14 tracks & treads Summer 2009 www.finning.ca managers Western Spaghetti By Martin dover A simple diagram can reveal wasted motion – and time – and get you started on the path to leaner operations There’s a lot of talk these days about improving productivity in the workplace. And if you’ve been listening, you’ve probably heard the word “lean” pop up. Just as the aim of your exercise routine is to get you trimmer and fitter, lean business philosophy aims to trim the fat in an organization. Lean practices have their origin in manufacturing, most notably in Japan’s Toyota factories, where managers learned to identify waste and streamline operations. “Even though the history of lean lies in manufacturing,” says Anurag Pandey, senior director of Alberta Finance and Enterprise’s Process Improvement Unit, “the principles are the same for processes that cross industries. There’s input and output and, in the middle, you add value for the customer.” Lean business practices aimed at eliminating various kinds of waste – such as transportation, over processing, inventory and space – can be applied to nearly every human enterprise. Look around your operation. Are you spending too much time getting your machines in and out of the shop yard to the worksite? On site, are your loaders travelling too far with a full bucket to the waiting truck? Does your in-house mechanic spend more time looking for tools than effecting repairs? Even if you run a tight organization, you have room to make efficiency improvements. If you’re just starting out, look for the easy-to-reach improvements. One tool to use is the spaghetti diagram, so named because once you’re done you might find your process looks more like a plate of spaghetti than a neat line taking your work flow from start to end points. “I like to start with the value stream mapping process,” Pandey says. “It makes problems a little more obvious. A spaghetti diagram is a supporting tool that shows one kind of waste: excessive transportation.” Managers usually know where problems lie. “There are other things you can measure, such as inventory buildup for example, that are not clear from this diagram,” Pandey says. “But, if transportation and material handling and movement are issues, a spaghetti diagram is a good idea.” And making a diagram like this is simple. Set aside a couple of afternoons, get a clipboard and some graph paper and follow an employee as he works. “Or, you could follow a part [or machine] through a process,” Pandey says. “It may travel miles because of shop or yard layout problems, material handling and storage issues.” If you are embarking on lean thinking, the spaghetti diagram is an easy place to start. Try it Now: Identify the time and process you aim to evaluate, not the name of the employee involved. Trace the path the employee or machine takes, counting the stops on the diagram. Assure the employee you are observing that you aren't evaluating him, just measuring and counting the steps he takes in a couple of hours of work. The diagram need not be to scale while you’re observing, but you will need to measure the distances later and add them up to measure transportation or movement wastage. Also make a note of why trips are being made – to retrieve tools? To move one machine out of the way to make room for another? Results may be eye-opening. Note any recurring obstructions in the path that the employee has learned to work around. www.finning.ca tracks & treads Summer 2009 32 15 tech A Fluid Solution By Jen Janzen There was a time when an oil change meant taking a machine offline for some TLC – now preventive maintenance programs ditch the downtime It’s a little decal that will go a long way towards worry-free machine operating. Finning introduced the PM Plus program to many of its general line machines earlier this year, giving owners a 2,000-hour membership in the preventive maintenance program that offers peace of mind, lower operating costs, better engine health and greater machine availability. A cornerstone of PM Plus is Finning’s new QuickEvac technology, which allows customers to purge hot oil, evacuate engine oil and then refill – all in a single maneuver onsite. There are no spills, the engine is pre-lubricated, and it’s hard to argue with the time savings. QuickEvac – or the more comprehensive MultiVac – condenses an oil change from a one- or two-hour affair into a cleaner, simpler 20-minute job. Doing your own oil and fluid changes won’t make a visit from a Finning technician obsolete. PM Plus provides three technician inspections: the initial at 250 or 500 hours, followed by a 1,000-hour visit and another at 2,000 hours. PM business manager Blaine Haukedal has dubbed this the “Work With Me” approach, turning preventive maintenance into a joint effort between customers and Finning support reps. “It drives out unnecessary cost,” Haukedal explains, pointing out that if a machine is in a remote location, the cost of having a Finning technician perform every oil change could add up quickly. Two hours of driving time every 250 hours could, over the course of a year, add up to about 16 hours – two full work days – of travel time. Forest industry workers will spot similarities between PM Plus and Forestry Extra, which gave owners six 1,000-hour inspections while the owners performed smaller-scale maintenance themselves. It’s another way Finning is helping equipment owners ensure their machines are expertly maintained while their balance sheets remain healthy. “Preventive maintenance is foundational to machine life,” Haukedal says. “You don’t have to do it, but you’re going to get caught if you don’t. The PM Plus program reduces operation cost while ensuring your components are regularly inspected by a Finning technician. It really is the best of both worlds.” QuickEvac and MultiVac are also available for older machines. The technologies can be added with a retrofitting kit. For more information, talk to your local Finning representative. How It Works: A cornerstone of Finning’s PM Plus program is the new QuickEvac system, which allows you to evacuate engine oil and then refill cleanly, quickly and safely. Here’s a peek under the hood. 1. QuickEvac pushes air through the works out of the filters and into the sump. 2. QuickEvac purges the filters and sump in under a minute. 3. Filter change is a breeze since the oil has already been purged. 4. The engine oil refills through the filters pressurizing the engine and, eliminating the need for the mechanic to climb up and down to take a reading. 5. A couple of minutes to reconnect the lines and you’re off to the races. 16 tracks & treads Summer 2009 www.finning.ca equipment Swiss Army Cat By Katherine Fawcett ILLUSTRATION by SCOTT DUTTON Finning provides tons of attachments, turning a single piece of landscaper’s iron into a fleet When François Fedorus takes time away from his busy landscaping company, he does what many Edmontonians do on a sunny weekend: yardwork. His passion is obvious and he enjoys being busy. As the owner and sole operator of FNF Services, Fedorus offers snow clearing and removal in the winter and landscaping services the rest of the year. For a small company, FNF Services’ equipment inventory list is long. Fedorus’s machines include a 304 excavator, a 242 B2 wheeled skid steer, a 277C multi-terrain loader, an IT24 F loader, two dump trucks, a pup trailer and more. His Cat tools include: rototillers, a brushcutter, post-hole auger, an angle broom and an angle blade, plus buckets and other tools for winter operations. He has also rented a trencher, landscape rake and a compactor. Fedorus relies on these attachments, rotating them depending on job requirements. “Attaching them and removing them is no problem with the hydraulic hoses and the quick couplers,” Fedorus says. His current favourite is the brushcutter. “It’s a big, very hungry lawnmower. It even goes through little trees and makes chips of them,” says Fedorus. He recently used his brushcutter, attached to the 277 multi-terrain loader, for clearing under power lines and for fence lines around farms. “You just attach and away you go.” Blades (Angle or Dozer) Stuff it does: Moves dirt, gravel, snow, livestock waste and other materials; sculpts and contours dirt Brag about it: Easy-tooperate angled or tilting front hydraulic blades Ideal for: Creating hills, ponds and garden beds for commercial, residential or recreational properties Bonus: Blades are easy to use with Cat joystick controls; heavier dozer blade has a six-way tilting function www.finning.ca Landscape Tiller Stuff it does: Pulverizes soil half a foot deep; mixes in compost; stabilizes and levels terrain Brag about it: Tungsten carbon bolt-on tines provide maximum strength, durability and quick changeability Ideal for: Residential and commercial landscaping; agricultural applications; golf courses Bonus: Spiral tine arrangement provides greater cutting performance Brushcutter Stuff it does: Clears rough overgrowth, heavy weeds, long grass and shrubbery Brag about it: Highstrength blades are tapered to allow cutter to ride up over stumps and rocks Ideal for: Highway medians; utility easements; clearing for houses, commercial developments or recreation areas; clearing pastures Bonus: Fully balanced blades minimize vibration For more information, visit www.cat.com/ landscaping Landscape Rake Stuff it does: Aerates, agitates, pulverizes and rakes soil; levels; removes rocks and debris Brag about it: Highstrength carbon steel rotating fingers, plus integrated hopper bucket for collecting debris Ideal for: Prepping land for sod or seed on sports fields and parks, residential and commercial developments Bonus: Operates with loader travelling in reverse to eliminate tire compaction in finely groomed soil Power Box Rake Stuff it does: Clears weeds, old lawns, overgrowth and debris; grades, levels, rakes and mills soil Brag about it: Endplates can be angled or remain parallel for close raking; blunt, pure carbide teeth create a dimpled subsurface pattern for seeding Ideal for: Trench restoration; golf course construction and sports field maintenance; commercial and residential landscaping; agricultural applications Bonus: Allows multiple applications with one machine tracks & treads Summer 2009 32 17 15 18 tracks & treads Summer 2009 www.finning.ca by Jesse Semko PHOTOGRAPHY BY Kelly redinger Regular maintenance can dramatically increase the lifespan of your yellow iron T ALL ABOARD: Andre Lavallee of Alta-Fab Structures climbs into his older, well-maintained IT62G loader www.finning.ca he wheels of a Caterpillar IT62G loader crunch over hard-packed gravel, kicking up dust as the machine rips across the shop yard at AltaFab Structures Ltd. in Nisku Industrial Park. Rocks fly into the air as the loader comes to a halt to hitch up to its load, a modular building that it begins to haul across a lot filled with similar metal-sided buildings. Alta-Fab Structures constructs pre-fabricated buildings that act as offices or living quarters at construction and oil and gas camps throughout North America. The company bought its first IT62G loader in 2001 to move the modular buildings around its 10-acre lot. Since then, that loader hasn't been out of operation, despite the fact that operators run it, often 10 hours a day, to keep up with orders. “We’ve never been without our loaders for any length of time,” says Andre Lavallee, facilities and equipment coordinator at Alta-Fab. “The Cat loaders have always been there when we’ve needed them.” Lavallee attributes the eight-year-old loader’s operational record to preventive maintenance: the proactive inspection program that maximizes the life of a machine and prevents unplanned, costly repairs or prolonged periods of downtime. The IT62G loader undergoes regular inspections – from checking the oil for traces of metal, which might indicate a loose bearing or premature wear, to replacing the oil filters and lubing the engine. These inspections are done like clockwork every 250 hours of operation with more detailed inspections conducted every 1,000 hours. PM inspections let Alta-Fab Structures know whether its equipment is operating properly, and it alerts management when equipment might require repairs. It also lets Finning perform scheduled repairs, which is always cheaper than trying to fix something after it has already broken down. By many accounts, a solid PM program can decrease repair costs and double or triple the life expectancy of a machine. “There is always a target life for equipment,” says Blaine Haukedal, preventive maintenance manager for Finning. “Preventive maintenance helps a machine hit that expected lifespan.” Haukedal likens preventive maintenance to changing the oil in your car. “It’s doing the right thing at the right time,” he says. “With your car, you’ve got to change your oil regularly, and rotate your tires and change your transmission fluid too. If you don’t perform those activities when they should be performed, you won’t get the most of your car.” tracks & treads Summer 2009 32 19 15 Built to Last YARD WORK: Andre Lavallee, left, and Jeff McDiarmid of Alta-Fab Structures with the old and new loaders The PM department at Finning helps clients get the most out of their machines. It caters maintenance offerings to customers’ requirements. With the “Do It For Me” contract, Finning takes care of all the maintenance services throughout the entire life of a machine. “A lot of customers want us to do that,” says Haukedal. “Usually these are small companies, who may not have the staff or expertise to handle regular repair or maintenance.” For customers that have some mechanical staff resources, there is the “Work With Me” contract. This lets a customer perform less specialized inspection and maintenance services while Finning handles more technical tasks – such as checking a machine inside and out for wear. “We take a look at the performance of a hydraulic system,” Haukedal says of a possible inspection scenario. “We’ll put the blade of the dozer up into the air and take measurements, every five minutes, to determine drift rates. If the blade is coming down, there might be a problem with the hydraulic system.” After every inspection, the customer gets a checklist outlining what was examined, as well as any areas of concern to be addressed. “We also provide a parts list. All a customer has to do is call our parts desk and they’ll arrange for their parts basket to be put together for pickup,” Haukedal says. One of the benefits of letting Finning handle all the maintenance services for Alta-Fabs’ Caterpillar equipment is that it provides a history for the company’s two IT62G loaders. “That definitely increases the resale value,” Lavallee says. Randy Megaw also knows the benefits that come from a PM program. As a manager at Calgary-based Ace Construction, he oversees maintenance of eight Caterpillar backhoes and three trackhoes that work 10 hours a day, five-plus days a week constructing power lines. All the machines are under a PM contract. “When we bought our machines, we looked into it and it made the most sense to let Finning do all our preventive maintenance work,” Megaw says. “Its a huge time-saver, like having a mechanic on staff all the time.” And so far, he continues, it has caught a few problems before they’ve developed into major headaches. In fact, during a recent PM inspection, something odd came back from the lab on the oil tests taken from two of Ace Construction’s trackhoes. For whatever reason, the final drives were going in both pieces of equipment and the oil testing caught the problem before it was too late. “It was an invaluable save,” Megaw says. “It caught the problem before the warranties expired.” The two trackhoes where taken to Finning’s shop to have the 20 tracks & treads Summer 2009 final drives rebuilt. In all, the early detection saved Ace Construction an estimated $20,000 and probably a week or two in unscheduled downtime. “It was pretty timely,” Megaw says. For Marvin Fenrich, equipment manager at KLS Earthworks Ltd., pairing with Finning to do maintenance on his company’s Cat equipment has proven ideal. KLS Earthworks has a number of excavators, dozers and rubbertire loaders that it uses to do civil infrastructure work for the City of Calgary. The equipment, most of which was purchased in 2004, often works 12 hours a day, six days a week on such projects as the construction of a cloverleaf overpass and the extension of a road system. While KLS Earthworks doesn't have the mechanical staff to handle major equipment inspections or repairs, it tries to be proactive. “The operators do a lot of little stuff,” Fenrich says. “Every day they go through a checklist, which we’ve set up.” Operators check fluid levels, make sure there are no hydraulic leaks and grease the machines. “We have a maintenance team in place that can handle minor mishaps, such as a broken hose.” However, for regular PM inspections and technical repairs, KLS Earthworks turns to Finning’s PM department. Fenrich likes this arrangement for several reasons. “It is an extra set of eyes. It makes sure that everything is done right,” he says. “But it also puts a little more responsibility on the Caterpillar dealership if a fluid level goes unchecked, or something else goes wrong.” The bottom line? Setting up a regular PM schedule shifts a little more of the liability onto the experts. And that’s always a good thing. MAINTENANCE TIPS MADE EASY Follow this five-step guide and your machine will keep on ticking, even after it has taken a licking. Read the manual – Every piece of Caterpillar equipment comes with one. This is your Bible. It spells out what needs to be checked on your machine, daily and weekly. “It creates the benchmarks that you follow and act from,” says Blaine Haukedal, preventive maintenance manager for Finning (Canada). “It tells you things that you need to do more often than every 250 hours.” Factor in the duty cycle – You need to understand the conditions your machine is working in. This is called the duty cycle. Is your machine working seven days a week, 24 hours a day in a dusty quarry? Or is it doing landscaping work? It determines how often and thorough you need to be when examining your equipment. Stay on schedule – Maintenance is one of the first things that gets pushed to the side when you’ve got a big job going. “It’s easy to say, ‘Oh, I can shut things down today;‘ then today turns into tomorrow, and the next day,” says Haukedal. But machine parts only last for a certain amount of time. Things will begin to bust. That’s the last thing that you want. Use the right fluids and filters – Gone are the days when you could buy generic oil and filters. Everything nowadays operates under higher pressures and hotter temperatures, and must meet standards set out for each piece of equipment. Cheaping out on oil and filters will affect the health of your equipment, and may also have warranty implications. Turn to the Experts – If you aren’t sure what you’re doing, talk to your Finning rep or turn to a skilled technician to prevent a major headache. www.finning.ca CONTROL ISSUES: Finning PM technician Peter Konrad inspects a generator control panel Don’t Fight the Power When it comes to backup systems powering crucial infrastructure, leave it to Finning by Jim Stirling PHOTOGRAPHY BY Darren Nisbet www.finning.ca I dentify an underserviced segment of an industry, customize a program to better address its needs and, voila, you have a new business tiger by the tail. It’s an approach that Richmond Power Systems, a division of Finning (Canada), applied recently when it instituted a planned maintenance system for emergency standby power generators. The new program has taken off in a big way in British Columbia and is expanding with equal promise into Alberta. Power supply is pretty reliable in Western Canada, to the point where most of us take it for granted. But when something goes awry, auxiliary systems are frequently called upon to pick up the slack, keep the lights on and vital systems functioning. And, when they’re needed, the backup systems had better work – and work properly. Consider a hospital. If there were a significant power loss with no reliable backup units to take over, the implications would be dire. But it’s not just hospitals that need emergency standby power units. tracks & treads Summer 2009 32 21 15 Don’t Fight the Power READY TO ROLL: PM technician Mike Todd performs a readiness inspection Data centres, airports, office towers, high-tech businesses, municipalities and regional districts are examples of other users. Finning has been servicing Cat standby generators for about 30 years, says Tony Heir, branch manager for Richmond Power Systems. For a good portion of those three decades, there was no program in place for scheduled generator servicing, Heir says. Typically, Finning would respond when customers called for service. “We looked at the market a few years ago and asked ourselves, ‘What if we could service all gensets, not just the Caterpillar units?’” he says. The more comprehensive approach came into sharper focus toward the end of 2007 when Finning acquired Collicutt Energy Systems. “Collicutt had a business unit that had significant gen-set servicing experience and access to markets,” recalls Heir. He started re-examining the concept of an all-manufacturer service system and how it might work. “We knew we had to build a business case if we wanted to attack this market. To do that, we pretty much had to start from scratch,” he says. “So, that’s what we started to do. We sat down and asked ourselves where the business was. We analyzed everything we could get our hands on.” The upshot was a sustainable business model that puts the maintenance of vital backup power systems on a regular schedule. Enter Finning’s Genguard Planned Maintenance Services. One of the key differences of the new system was the creation of a staff, a structural 22 tracks & treads Summer 2009 system, and parts and service geared exclusively to putting the maintenance of backup power systems front and centre. It’s not a sideline; it’s what Richmond Power Systems does. A byproduct feature of Genguard is a geographical rationalization, explains Heir. “The service technicians know where they’re going. We plan routes for them up to 14 days in advance. It helps maximize their efficiency.” Another feature of Finning’s streamlined Genguard system makes life easier for harried property managers. Customers sign up at a predetermined rate for a one-, two-, three- or five-year contract period. Finning takes care of all the administration and service scheduling, Heir says. The customer doesn’t have to worry. “We call up the customer and ask them when, during the next week, we can come and do the scheduled gen-set servicing.” The customers know what they’re getting and when they’ll get it. The technicians’ work also meets all pertinent codes and standards, including CSA compliance, to ensure the backup units are always well maintained and fully functioning, Heir adds. The Genguard program has been very well received in the marketplace and the service niche has rapidly expanded. The numbers of trained technicians responsible for the field work, for example, has mushroomed from two to nine. More are likely to come aboard in the future – and they’ll be busy. “We don’t see the technicians much in the building,” Heir says with a smile. It has taken a team to put the Genguard program together and make it function smoothly, explains Heir. “It’s been a lot of hard work for all our technicians and those brought over through the acquisition, especially during the first four months of transition, working with a different company and methodology,” Heir says. “Everyone worked their butts off.” He singles out for special thanks, Mike Baker, PM sales services supervisor, Angelo Petovello, PM sales representative and Laverne McGowan, service coordinator. Petovello zips around to his appointed tasks in a sporty Mini Cooper, decaled like a Finning service truck. Heir says the car is not only great eye-catching advertising for Finning, it’s also highly practical for the business at hand: it’s super-handy in tight spaces and accesses Petovello frequently encounters and it uses little gas. MINI CAT: Mike Baker, PM services supervisor and Angelo Petovello, PM sales representative www.finning.ca CHECK OUT A CHECKUP WON'T HURT A BIT: Aljo Hamzagic, another Finning tech, takes a routine sample of oil for analysis at the lab And operating on the premise that imitation is a sincere form of flattery, Heir notes the competition, which never had a dedicated salesperson for servicing backup generators before, quickly changed its tune when Finning came on the scene. But the most important response to the Genguard system comes from the customers it serves. The growing Township of Langley, in B.C.’s Fraser Valley, is a Finning customer. It has in excess of 30 standby generators with four added in the last year to accommodate growth, says John McQueen, Langley’s equipment maintenance manager. The units provide backup electrical power services to a variety of vital municipal buildings and services, such as the RCMP detachment, the operations building, municipal hall, water and sewer utilities and eight fire halls. The Township of Langley has a five-year agreement with Finning, which involves a dedicated maintenance schedule for each gen-set. McQueen explains that Langley took the Finning service option rather than handling the work in-house for three reasons. “One, Finning looks after our service scheduling for us,” he says. “Two, because of rapid growth in the Township, we had to look closely at our liability risk, and three, we do not have the technical background or equipment required.” Finning does. The agreement with Finning works well, he reports. “There’s good communication with Finning and there’s consistency, often with the same service technician, who gets to know our systems well.” www.finning.ca Ensuring that backup power generating systems are always primed to deliver on demand is what Richmond Power Systems is all about. On each prescribed visit to a customer by an experienced Finning technician, each standby generator unit is subject to a rigorous list of checks and testing procedures. “There is a mandated annual service and more frequent options customers can choose from,” summarizes Gord Carleton, a service technician in the preventive maintenance department of Richmond Power Systems. The annual full service procedure is a comprehensive exercise. It includes ensuring each customer’s standby unit meets all fire code standards for emergency generators. Oil, filters and safety features are checked on a test list comprising more than 50 items. Another requirement is load level testing. “We crank up the generator to 100 per cent load and run it for two hours,” explains Carleton. It’s the same principle as test driving a vehicle at highway speeds before deciding to buy it. Customers can opt for further levels of service with Finning every six months or on a monthly basis, he continues. Each service category requires a thorough check of each unit and running it with or without load to ensure it’s in good shape. “We look after 10 or 15 different types of unit, not just Caterpillar, and that takes a bit of experience,” he says. The same level of experience helps prevent problems before they develop. Block heaters on the backup units, for example, run 24/7 and hoses need upgrading. And about 90 per cent of service calls received by Finning with this work are connected to dead and dying batteries, adds Carleton, a heavy duty mechanic by trade who has been doing this type of work for more than 10 years. Updating or replacing these items before they fail is sound preventive maintenance practice and can save the customer much grief and money. tracks & treads Summer 2009 32 23 15 FAMILY TIES: Lake Excavating's Trevor Seibert and Kari Gertzen have what it takes to keep the family business humming Placid Lake by Noémi LoPinto PHOTOGRAPHY BY CRAIG smith A sister-and-brother team keep the family business running smoothly in Williams Lake, B.C. L ake Excavating Ltd. is more than a family business for Kari Gertzen and Trevor Seibert, it’s a legacy they hope to pass on to their children. “Obviously we’re invested in keeping the company as a family business,” says Gertzen, vice-president and finance manager. “You develop a sense of pride and accomplishment, especially since Lake Excavating has been around for so long.” The company began in 1964, when Romanian-born Karl Seibert bought some yellow iron and went to work excavating around Williams Lake, B.C. He married a Canadian girl named Reta and their children, Kari and her younger brother Trevor, grew up surrounded by dozers and excavators. As soon as Trevor was old enough, he was running machines. Kari spent a summer installing sewer and water lines and also worked in the office. “I did like the equipment,” says Gertzen, 43. “It felt normal to me to be around it.” 24 tracks & treads Summer 2009 Today, the company has a fleet of 70 pieces of heavy equipment, most of which are Cat. Through the siblings’ development company, Avion Developments Inc., and Lake Excavating, they undertake a number of design-build projects in B.C. and Alberta, such as engineering, infrastructure and other work on a 43-acre commercial subdivision in Williams Lake; a new Walmart; a design-build for Highway 20 west of Williams Lake; a 180-unit manufactured home park; a 72-acre rural development in Whitecourt, Alberta and other ongoing projects. Recently, Gertzen and Seibert purchased two 330Ds from Finning, which will come in handy for the development of the Walmart site. It’s a $25-million project for a 118,000-square-foot super centre, opening in November. The project is good for the local economy; Lake Excavating has subcontracted local companies for engineering, www.finning.ca curb and gutters, electrical and landscaping. In 2008, Lake hired 35 additional employees to run two shifts a day, seven days a week to service the site. In 65 days, Lake moved 600,000 cubic metres of material, including 100,000 cubic metres of blasted rock. “It’s a great accomplishment,” says Gertzen. “And it’s nice to be able to do something like that in the town where we were born.” Lake Excavating employs between 35 and 50 regular staff during summer and as many as 15 during winter, a core group of guys, some of whom have been with Lake for close to 10 years. “It adds to the family feeling,” Gertzen says. Adding to the family feeling is the relationship with Finning (Canada), dating to 1964, when Karl Seibert purchased a 955 track loader with a backhoe. Since then, the company has purchased more than 400 Caterpillar machines. “Finning is usually quick to get us what we need,” says Gertzen. “My dad became friends with more than one Finning manager. Dealings with them are part of the legacy.” Finning in Williams Lake is a full-service branch including parts, service and sales. Lake Excavating is one of the parts department’s largest customers. And in 2008-09, Lake Excavating purchased two 320DLs, one 312CL and two 330DLs. Product support salesman Shane Elzinga deals with Lake Excavating on an almost daily basis. With Elzinga, Lake participates in several of Finning’s product support programs, including oil sampling, track wear and technical support to Lake’s head mechanic in regards to hydraulic issues. “It means our mechanics can obtain the information they need to conduct ongoing maintenance,” Gertzen says. With experience in banking and financial management, Gertzen had been running the Lake Excavating head office in her hometown since 1989. Trevor ran his own company (which he still owns), and worked for Karl in various capacities. The siblings bought their father out in 1996. Gertzen still runs the head office in Williams Lake, does all the company finances and runs Lake Excavating’s safety program. She obtains the bonding and insurance that’s required when bidding on publicly tendered projects and she occasionally conducts field safety and orientation meetings. A one-stop shop, Gertzen says the company offers a “full package” to their customers. CLEANUP ON AISLE FOUR: Lake Excavating prepares the site for a 118,000-square-foot Walmart Super Centre www.finning.ca SIBLINGS IN SPEED Trevor Seibert and Kari Gertzen are more than a sister-and-brother business team. They also own and staff a NASCAR team, which takes them to racing competitions all over the country. Trevor is the driver and Kari is the team manager. Since qualifying for his Players/GM Series in 1991, Trevor has been competing against some of the world’s best drivers in the NASCAR Canadian Tire series. He races in the Formula Atlantic division of formula auto racing, Indy Lights class of open-wheeled race cars or the Players/ GM Camaro class. At Calgary’s Race City in the mid-1990s, Trevor broke a world track record for fastest time on any half-mile. The siblings recently competed in the NASCAR Canadian Tire race at Mosport in Toronto. Trevor and Kari came in 14th out of a 24-car field, in a 52-lap race that reached speeds of 180 miles per hour. Now president and general manager of Lake Excavating, 42-yearold Trevor does onsite project supervision and serves as company estimator, managing pricing, quotations and tendering. Trevor also has a commercial pilot’s license and, in one of the coolest commutes, flies crew and equipment in the company-owned Piper Navajo 7 between Williams Lake and Whitecourt. “He’s skilled at his job and I am skilled at mine, and neither of us wants the other’s job,” says Gertzen. “We have similar philosophies of business, different duties and we respect each other’s assets. That’s why it works so well.” As a woman in construction, Gertzen is a bit of an anomaly, but increasingly less so. “I talk to more women in this field than there were 10 years ago,” she says. “We’d be kidding ourselves to think it’s not a man’s world. Once in a while I still get ‘what would she know,’ but you’d get that anywhere.” Gertzen says being surrounded by guys has taught her a straightforward way of communicating. “I don’t mince words,” she says. “Trevor and I both have that quality. I think that’s important in business.” Gertzen has two sons, 14 and 17, and Seibert has a 17-year-old son and a daughter halfway through her post secondary studies. All four have worked for the company. The 17-year-old cousins are skilled operators already. But, of course, Seibert women are no slouches. “Trevor’s daughter, Brittany, is working for us this summer, running the backhoe loader and articulated rock truck,” says Gertzen. Grandfather Karl, who still consults for the company now and then, is justifiably proud. tracks & treads Summer 2009 32 25 15 Keep It Up (and Running) Finning’s new Gas Engine Exchange program swaps out engines to be overhauled and replaces them so fast your head will spin by Robin BruneT A side from setbacks caused by the recession, natural gas production in Alberta continues to be a key economic driver. An estimated 12 billion cubic feet is extracted daily from more than 92,000 wells in the province, with two-thirds of that total going directly to the all-important U.S. market. Increased production efficiency is an ongoing goal, and given the fierce competition in the gas compression sector, the one word nobody wants to hear is “downtime.” That’s why a growing number of oil and gas producers are turning to Finning (Canada) for help. The Gas Engines Exchange Program is saving natural gas producers money by minimizing the downtime caused by on-site engine overhauls. Instead of enduring lengthy on-site overhauls, program participants simply contact Finning for a swing (replacement) engine. Finning technicians deliver and install the remanufactured engine on the worksite. The tired engine core is taken away for remanufacturing for future use. “We launched the program in 2008, and it’s already grown at a faster pace than projected,” says product manager Ehtisham Anwer. “The advantages of the program are substantial: remanufactured engines are only 60 to 70 per cent of the cost of new engines, they can be installed in a short time with less on-site labour, and they’re rebuilt to Caterpillar specifications by certified technicians using genuine Caterpillar parts.” Canadian Natural Resources, one of Canada’s largest producers of natural gas, was instrumental in developing this program. “CNR officials approached Finning in 2007 because they were running in excess of 90,000 hours on their engines,” says Finning product support sales representative Chris Paliwoda. CNR officials were worried about 26 tracks & treads Summer 2009 the downtime of the hard-working engines that were due for overhauls. They needed a quick turnaround for their engine rebuilds. After working with CNR to determine the parameters and content of the exchange program, Finning put in place a startup exchange inventory of G3304, G3306 and G3408 engines. “The first transaction with CNR took place in April 2008,” says Paliwoda. “Our knuckle boom truck with a replacement engine arrived at a CNR compressor building at 9 a.m. as scheduled. The old engine was disconnected, and replaced by a remanufactured G3306 engine. The replacement engine was up and running by 5 p.m. that same evening.” Since then, several customers in Alberta and British Columbia have benefitted from the remanufactured gas exchange engines. Finning’s Edmonton facility now offers replacement rebuilds on all variants of the G3300, 3400, 3500 and 3600 engines, and Paliwoda describes them as “close as possible to plug-n-play as you can get.” There are thousands of gas engines operating in Finning’s territory, from small G3300s of 220 bhps to large G3600s of 2,270 bhps. The production power of these engines is considerable: a G3600 averages $1,000 worth of gas production per cylinder, or $12,000 per hour. Under normal field operations, an average engine nets in excess of $35,000 per week. www.finning.ca BUILT TO REBUILD Finning’s Etisham Anwer points out that a simple phone call is all it takes to access the full range of services offered under the Gas Engines Exchange Program. Engines that need overhauling are disassembled and inspected in Finning’s shop, a process that is less costly and far more reliable than the standard method of disassembly on the customer’s site. Consultation is key to the customer getting exactly what he wants out of a rebuild, but as desirable as custom rebuilds may be, busy clients can opt for an off-the-shelf overhauled engine, which comes with a core credit. “This is a credit for engine cores based on a charge levied when a rebuilt engine is purchased,” Anwer says. “It takes effect when the replacement core is returned at a later date for overhauling and helps make total acquisition costs a lot less than if the client were to purchase a brand new engine.” The remanufacturing process includes engine disassembly, inspection, machining and assembly. Continuous inspection and testing during the process ensure the quality and reliability of remanufactured engines. These tasks are carried out in a controlled environment with production tooling and qualified personnel for a cost-effective and reliable product. A typical overhaul under the Gas Engines Exchange Program encompasses basic engine as well as auxiliaries. The basic engine includes cylinder block, crankshaft, piston rings, connecting rods, cylinder liners and heads, valve train, camshaft, front gears and cover, fly-wheel housing and seals and gaskets. Engine auxiliaries include water pump, turbochargers, oil pump and cooler, exhaust manifold, governor drive and magneto. Finning offers two pricing options for gas exchange engines: Service Plus (EX) This option has a lower up-front cost followed by additional charges which may vary depending on the condition of customer’s core. Additional charges apply whenever non-essential parts require replacement or machining. Before Failure (BF) This option has a higher upfront cost but the risk of extra charges are lower (the customer gets a more certain cost). Additional charges apply only when crank and/or cylinder block require replacement. “Since Before Failure pricing is based on the average cost of additional changes,” says Anwer, “the overall cost to the customer under both pricing options averages out to be same at the end of the day.” Optimal inventory management and shortened cycle times are critical to ensure that an engine is available when a customer needs one. “The majority of these engines out there have been running for several years and do not have the current technological advancements. With the engines exchange program, several customers have upgraded old engines to current technology to go greener,” says Anwer. He says although the economy is beginning to improve, saving money is still a priority for his customers. “It always will be, along with a minimum of fuss and a maximum of production efficiency,” he says. “Our Gas Engines Exchange Program satisfies these objectives. That is why it’s a real success story, but we think that the story’s only begun.” www.finning.ca tracks & treads Summer 2009 32 27 15 Meeting the Challenge 28 tracks & treads Summer 2009 www.finning.ca Testing Teck photography by jody M. crawford In 2009, Finning’s Sparwood, B.C. location became a proud supporter and sponsor of the Mine Rescue and First Aid Competition. Put on by the East Kootenay Mines Industrial Safety Association, the friendly competition is designed to test – and celebrate – the emergency response and rescue abilities of teams in the area. “We supplied the venue,” says Mike Brandt, Finning’s customer service manager at Sparwood. “Plus, we had a lot of props and equipment at our disposal.” Teck Coal, the biggest player in the region, was behind all five East Kootenay teams: Fording River, Greenhills, Coal Mountain, Line Creek and Elkview. Greenhills moved on to the provincial competition. 1. TRIAL BY FIRE: For the fire task, teams had to safely stow their vehicles, quickly gear up, know procedures and deal with the fire. 2. KNOW HOW: The Coal Mountain team demonstrates the form that could one day save lives. 3. IN KNOTS: In this simulation, a logger has been injured and is stuck at the bottom of a hill under a felled tree. The rope task demonstrates a team’s ability to repel down a hill with safety equipment, arrange another system of ropes and pulleys to remove the tree from the injured man’s leg, then get him back up the hill. 4. THE WATCHERS: Judge Patrick Milan observes a team on the fire task, watching for techniques in extinguishing the fire, from equipment to nozzle settings. 5. TEAM OF THREE: In this three-person first aid test, one person has fallen off a dozer and is lying unconscious, a second has injured her leg atop the dozer and – in the midst of it – a frantic supervisor drops with an apparent heart attack. It tests the team’s ability to call for the right equipment and to prioritize. 6. TIE TIME: In this bench task, a judge checks a team’s ropes and knots. 7. NOT SO GREEN: The captain of Greenhills confers with his teammates. Judges look for good teamwork. www.finning.ca tracks & treads Summer 2009 32 29 15 by keith haddock GREENE GOES YELLOW: This 48-year old SA-40 paver was typical of the machines that brought Barber-Greene to the forefront of the asphalt paving industry THE MOD SQUAD: Caterpillar’s modern pavers are represented by the AP655C. This, and the current AP655D, is equipped with a 174-horsepower engine Blacktop Experts Caterpillar faced down the last recession by branching out into new products – among them, the paver Caterpillar’s paving products continue a tradition of efficient and high-quality paving, building on the efforts of industry experts from the Illinois company that offered the very first machine to combine the mixing and placing of asphalt in a single operation. In the depths of the mid-1980s recession, Caterpillar management believed that adding new products to increase its customer base would hasten recovery. Consequently, by the end of that decade, Caterpillar had successfully broadened its product line to include articulated dump trucks, loader-backhoes, log loaders and paving equipment. These products proved effective in leveraging Caterpillar’s advantage and ensuring it emerged strong from those economic downtimes. Caterpillar’s first paving machines appeared in 1985 when the company entered into a branding agreement with CMI Corporation. At that time, CMI had recently purchased Raygo Corporation of Minneapolis, Minnesota, and the highly-respected CMI pavers, along with the former Raygo compactors, were marketed as Caterpillar machines. In 1988, the company established Caterpillar Paving Products, Inc. in Minneapolis, where its paving products are still built today. CMI Corporation was founded in the early 1960s by Bill Swisher who introduced the “Auto-Grade,” the first automatically controlled fine-grade trimmer that permitted highly accurate, final-grade preparation. In 1964, Cat introduced this machine, which paved the way for a series of automated concrete and asphalt paving machines that would become highly respected in the industry. In 1991, Caterpillar further boosted its paving product line by purchasing the Barber-Greene Company of 30 tracks & treads Summer 2009 Aurora, Illinois. Founded in 1916, no company had more experience designing asphalt paving machines than Barber-Greene. In 1931, its founders, Harry H. Barber and William B. Greene, invented the first machine to mix and place asphalt in one operation. It prompted a rapid rise in paving productivity to accommodate the more than nine million automobiles and trucks then on the roads in the United States. Paving machines earned an excellent reputation for reliability and efficiency, which helped the company gain international status. And, because of the highly-regarded Barber-Greene name, Caterpillar continued to build and market the machines as BarberGreene products after it took over the company. Since acquiring paving machines in the mid-1980s, Caterpillar has continued to develop new features and keep its pavers at the forefront of current technology. Caterpillar offers both wheeled and tracked paving machines. They are all equipped with self-diagnosis on propel and feeder systems, and an independent feeder system to reduce segregation and hand work. Operators can position dual operating stations beyond the machine’s width for maximum visibility. Screeds boast a hydraulically-operated width adjustment for paving widths up to 7.3 metres, and the screed pads are electrically heated. Wheeled pavers offer an optional bogey wheel assist to enhance rimpull and traction. Tracked pavers are a dream for operators, providing superior traction and stability, as well as consistency of placed material when wide screeds are used or when carting high capacity loads of asphalt. Like much Cat iron, pavers offer a choice of metal or rubber tracks, depending on the application. www.finning.ca Portrait: Bob Fritchey photograph by Ricardo Alberto Leiva Ectem quat et ing estrud magnim dolute volore magna utat Osto con et ing et ea adip erat et, velestrud magnis atue “I repair broken machines,” Bob Fritchey says plainly. “I troubleshoot for customers to find the problem.” A 36-year Finning veteran, 21 of those years in Fort St. James, B.C., Fritchey is understating his responsibilities. His title “resident field mechanic” doesn’t adequately describe what he and other guys like him do for a living. “A resident field mechanic takes care of everything,” says Fritchey’s supervisor, Dave Pitkethley. “Bob is the initial – and often only – customer contact point.” His skills extend past the underthe-hood variety. “He’s responsible for safety, billing, cost efficiency and shipping,” says Pitkethley. Fritchey is also part salesman, who has to respond to customers’ needs and sell certain services or approaches to increase customers’ uptime. Over long distances, these aren’t easy tasks. “Once, I drove four hours through a blizzard at night to change a fuse. Turns out it had been mislabeled,” Fritchey says. “Then I turned around and drove four hours back.” www.finning.ca tracks & treads Summer 2009 32 31 15 New Produc ts and Services from Finning Look forward to your next oil change Our new QuickEvac system empties most diesel engine sumps in less than a minute, enabling you to do a complete lube, oil and filter change in a mere 20 minutes. It’s also safer: you empty and refill the oil from a single point, which means you don’t have to climb up and down machines. With QuickEvac, dry starts are no more – the engine is prelubricated before cranking begins. It’s the fastest, cleanest oil change you’ve ever completed. Talk to your Finning (Canada) rep for more details about this program. Easy armour cuts downtime Protect your buckets, blades and boxes with Cat’s mechanically attached wear plate system – MAWPS. Easy to install, MAWPS takes just minutes to change out. Wear plates, like disposable razor blades, simply slide in. When it's time for fresh sacrificial iron, say goodbye to hammering or welding: a screwdriver is all that’s required. Ask your local Finning representative how you can reduce operating costs with MAWPS today. 32 tracks & treads Summer 2009 Caterpillar machines are built to be rebuilt The extensive Caterpillar Certified Rebuild program incorporates the very latest Cat technology and critical engineering updates into your machine at a fraction of the cost of buying new. After a thorough evaluation, including more than 350 tests and inspections and the automatic replacement of approximately 7,000 parts, you get a like-new machine and warranty. Be a filter connoisseur During the dusty construction season, what’s the best way to increase component life and lower operating costs? Keep your fluids clean. Moving to high efficiency filters is one way to end the headaches. Cat filters help ensure fluid cleanliness because their synthetic, smalldiameter fibres trap smaller particles and hold more debris. All filters are not the same. Even tiny particles know the difference, so should you. www.finning.ca www.finning.ca www.finning.ca tracks & treads Summer 2009 32 33 15 Count on Us THE MACHINES THAT BACK OUR FIGHTING MEN This image comes from a vintage wartime Caterpillar magazine advertisement. In the ad, the accompanying text waxes about an operator’s love for his Cat: The feeling of a soldier for the equipment he works with is something special. Watch a hard-bitten “skinner” – a man who handles earthmovers – around his Cat Bulldozer or Motor Grader or wheel Tractor. When he touches the machine, it’s like a man laying his hand familiarly on his hound dog’s head. There is a deep affection and understanding. Some things never change. 34 tracks & treads Summer 2009 www.finning.ca Ability to keep you up and running Try us on for Size. We’re the perfect fit. Receive a *FREE pair of Cat work boots when you set up a rental account and spend your first $1000 on rentals. *Some conditions may apply. See in-store for details. Boots may not be exactly as shown. We have your rental needs covered, whether you’re temporarily replacing a fleet machine that’s in for repair, needing a specific machine for a special application over the short-term or testing a new machine before making the decision to purchase. Machines, work tools, lifts, tools— whatever you’re in need of, The Cat Rental Store is equipped to meet your requirements. With over 35 rental locations throughout B.C., Alberta, Yukon and Northwest Territories, your rental can be found just around the corner. Call 1-866-285-5550 or visit us online at www.catrents.ca to view our entire catalogue of offerings. 32 Work Smarter, Not Harder Receive $1000 toward your 2nd work tool purchase with the purchase of your new machine. See your Finning sales representative for complete details. * Machine versatility is the key to maximizing productivity - using the right tool for the job saves time and money. Tackle a wide range of demanding construction and industrial applications with performance-matching Cat work tools. For even greater flexibility, many of these work tools can be used on other Cat compact equipment, including compact wheel loaders. With well over 30 different applications, we’re sure we have the right tool for your job. Ask your sales representative about your specific application. * $1000 credit may not be applied to previous purchases or work orders. Coupon must be submitted at time of original purchase in order to be credited to account. Program ends August 31, 2009. Cannot be combined with any other offers. 1-888-finning | finning.ca (346-6464)
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