SACEA Open Cast Production Optimisation Case Study

Transcription

1 An ISO 9001:2008 Certified Company SACEA Open Cast Production Optimisation Case Study Date: 08 Sept Mining Consultancy Services (Pty) Ltd Ref:

2 MCS Divisions -Exploration -Concept study -Pre feasibility -Feasibility -Project Commissioning Consultancy Services Technology - Machine Monitoring - Specialised Software - Hand Held PDA HQ In Bryanston Productivity Optimisation MineSite Technologies Training and Coaching - Mining Process Training - Mine Planning Training Mining Consultancy Services (Pty) Ltd

3 MCS Track Record (Optimisation) Clients and Projects +20 Years Experience World Leaders +40 Projects Rapid Pay-back Mining Consultancy Services Pty Ltd Mining Consultancy Services (Pty) Ltd. 2016

4 Glencore TOC Timeline Dec 2015 Jan 2016 May 2016 Jun 2016 Mining Consultancy Services (Pty) Ltd

5 Background Phase 1 Aims: Introduce ProdMate management reporting system Amalgamate all the data sources to produce holistic reporting Develop logic and software for reporting purposes Develop the various reports for different management levels Dragline Excavator Truck Bin/Plant Mining Consultancy Services (Pty) Ltd

6 Process Components Primary Machines Trucks Loading Area (Bin) Processing (Plant) Mining Consultancy Services (Pty) Ltd

7 Dragline Report Mining Consultancy Services (Pty) Ltd

8 Dragline Reports A shift B shift TOC - Weekly Report - Week 36, 2016 Production KPI's Target Week 31 Week 32 Week 33 Week 34 Week 35 Week 36 6 week avg Production KPI's Target Week 31 Week 32 Week 33 Week 34 Week 35 Week 36 6 week avg Shift Production change C shift over KPI's time (min) 0Target Week Week Week Week Week Week week avg Shift change over time (min) First Shift swproduction ing change D Late shift over (min) KPI's time (min) 0 0Target 110Week Week Week Week Week Week week avg First sw ing Late (min) Last First swshift ing swproduction ing Early change Late (min) over (min) KPI's time (min) 0 0 0Target 14 9 Week Week Week Week Week Week week avg Last sw ing Early (min) Avg Last number First swshift ing of ing Early change swlate ings (min) over (min) time (min) Avg number of sw ings Avg Avg cycles Last number First sw per sw cycling of Early swlate ings hour (min) (min) , , , , , , , Avg cycles per cycling hour 60 52,89 57,09 48,26 52,18 51,62 48,26 51,72 Avg Avg bucket Avg cycles Last number load sw per (BCM) cycling of Early sw ings hour (min) ,16 54, ,16 60, ,93 45, ,31 52, ,63 50, ,94 47, ,86 51, Avg bucket load (BCM) 48 43,14 45,3 41,77 45,23 44,81 47,17 44,57 Avg Avg payload Avg bucket Avg cycles (Tonnes) number load per (BCM) cycling of sw ings hour105, ,75 41,33 56, ,36 42,34 58, ,84 40,44 42, ,48 45,16 58, ,59 43,73 52, ,86 45,82 53, ,48 43,14 53,61344 Avg payload (Tonnes) 105,6 94,92 99,66 91,89 99,51 98,58 103,76 98,05 Avg Avg TCM Avg payload Avg bucket cycles (Tonnes) load per (BCM) cycling hour , ,52 90,92 44,37 47, ,2 93,14 49,07 53, ,56 88,96 39,53 47, ,7 99,35 47,37 45, ,43 96,21 47,41 46, ,96 100,81 49,17 45, ,73 94,9 46,15 47,6 Avg TCM , , , , , ,2 Avg Avg fill Avg length TCM Avg payload bucket (Tonnes) load (BCM) ,648 27, ,62 44,72 28, ,42 107,95 44,79 26, ,68 86,96 42,86 26, ,6 104,21 44,4 25, ,1 104,3 46,83 25, ,16 108,17 52,31 26, ,66 101,54 45,98 Avg fill length 25 24,68 25,43 30,04 26,2 26,01 24,65 26,17 Time Avg Summary Avg fill Avg length TCM payload (Tonnes) ,6 24, ,64 98,38 25, ,44 98,54 29, ,19 94,3 25, ,19 97,68 26, ,39 103,03 26, ,04 115,09 26, ,98 101,17 Time Summary Operating Time Avg Summary Avg time fill length TCM , , , , , , , , , , , , ,51 Operating time Operational Operating Time Avg DT Summary time fill length , , , , , , ,03 Operational DT Planned Operational Operating maintenance Time DT Summary time Planned maintenance Unplanned Planned Operational Operating maintenance DTtime Unplanned maintenance Planned Unplanned Planned DTOperational maintenance DT Planned DT Unplanned Planned Unplanned Planned DT maintenance Unplanned DT Unscheduled Unplanned Planned Unplanned time DT maintenance Unscheduled time Idle Unscheduled time Unplanned Planned time DT Idle time Total Idle Minutes Unscheduled time Unplanned time DT Total Minutes Variance Total Idle Minutes Unscheduled time time Variance Shifts Variance wtotal ith Idle usable Minutes time data Shifts w ith usable data Cycle Shifts Analysis Variance wtotal ith usable Minutes Timedata Cycle Analysis Time Avg Cycle swshifts ing Analysis Variance time w ith (sec) usable Timedata Avg sw ing time (sec) Avg Avg fill Cycle time swshifts ing (sec) Analysis time w ith (sec) usable Timedata Avg fill time (sec) Avg Avg return Avg fill Cycle time sw ing (sec) Analysis time (sec) Time Avg return time (sec) Avg Avg dump Avg return Avg time fill time sw (sec) ing (sec) time (sec) Avg dump time (sec) Avg Avg dump Avg return time fill time (sec) (sec) Avg Avg dump return time time (sec) (sec) Avg dump time (sec) Mining Consultancy Services (Pty) Ltd

9 Excavator Reports A Shift Production KPI's Target Week 31 Week 32 Week 33 Week 34 Week 35 Week 36 6 week avg First Load Late (min) B Shift Last Load Early (min) Production KPI's Target Week 31 Week 32 Week 33 Week 34 Week 35 Week 36 6 week avg Avg number of loads First C Shift Load Late (min) Avg loads per hour 16,9 9,84 11,56 13,54 14,68 10,82 9,95 11,63 Production Last Load Early KPI's (min) Target 0 Week Week Week Week 2 34 Week Week week 4 avg Avg BCM's First Avg D Shift number Load Late of (min) loads Time Summary Last Avg Production loads Load Early per KPI's hour (min) Target 16,9 0 Week 13, Week 12, Week 11, Week 8, Week 7, Week 9, week 10,41 2 avg Operating time Avg First number BCM's Load Late of loads (min) Operational Delay Avg Time Last loads Load Summary Early per hour (min) 16,9 0 14, , , , , , ,14 21 Planned DT Operating Avg BCM's number time of loads Unplanned DT Time Operational Avg loads Summary per Delay hour 16, , ,64 0 9,5 0 14, , , ,08 4 Unscheduled time Operating Planned Avg BCM's DTtime Idle time Operational Unplanned Time Summary DT Delay Total Minutes Planned Unscheduled Operating DTtime time Variance 0 0 Unplanned Idle Operational time DT Delay Shifts w ith usable data Unscheduled Total Planned Minutes DT time Idle Variance Unplanned time DT Total Shifts Unscheduled Minutes w ith usable time data Variance Idle time Shifts Total Minutes w ith usable data 660 Excavator EX Weekly Report For Week , 2016 Variance Production KPI's Target Week 31 Week 32 Week 33 Week 34 Week 35 Week 36 6 Week Avg Shifts w ith usable data First Load Late (min) Last Load Early (min) Avg number of loads Avg loads per hour 16,9 13,16 11,89 11,43 12,6 10,46 9,82 11,58 Avg BCM's Time Summary Operating time Operational Delay Planned DT Unplanned DT Unscheduled time Idle time Total Minutes Variance Shifts w ith usable data Mining Consultancy Services (Pty) Ltd

10 Truck Reports TOC TRUCK PERFORMANCE OVERVIEW Week 36, 2016 Truck Total Tips Avg. Operating Time Avg. First Tip (MIN) Avg. Last Tip (MIN) Avg. Number Of Tips T ,7 15,7 35 T ,5 80,2 30 T ,2 49,6 30 T ,4 81,6 29 T ,3 77,5 28 T ,4 102,8 25 T ,4 64,4 21 T , T ,5 60,3 19 T ,4 18 T ,4 96,6 17 T ,1 66,4 17 T ,5 107,9 17 T T ,7 73,5 13 T ,1 13 T ,7 136,2 12 T ,4 57,6 11 T ,1 78,9 11 T ,8 72,2 10 T ,5 10 T ,4 49,9 9 T ,5 31,1 6 T , T Mining Consultancy Services (Pty) Ltd

11 Bin/Plant Reports A shift B shift TOC - ROM Tip Weekly - Week 36, 2016 Production KPI's Target Week 31 Week 32 Week 33 Week 34 Week 35 Week 36 6 week avg Production KPI's Target Week 31 Week 32 Week 33 Week 34 Week 35 Week 36 6 week avg Shift Production change C shift over KPI's time (min) 60 Target Week Week Week Week Week Week week avg Shift change over time (min) First Shift Tip Production Late change D (min) shift over KPI's time (min) 0 60 Target -3 Week Week Week Week Week Week week avg First Tip Late (min) Last First Tip Shift Tip Early Production Late change (min) (min) over KPI's time (min) Target 1-8 Week Week Week Week Week Week week avg Last Tip Early (min) Number Last First of Tip Shift tips Tip Early Late change (min) (min) over time (min) Number of tips Tips Number per Last hour First of Tip tips Tip Early Late (min) (min) , , , , , , , Tips per hour 18 15,68 31,61 24,53 23,19 21,84 15,49 21,15 Avg Tips Tonnes Number per Last hour of Tip tips Early (min) , , , , , , , Avg Tonnes Avg Avg Scaled Tips Tonnes Number per Tonnes hour of tips , , , , , , Avg Scaled Tonnes Time Avg Summary Avg Scaled Tips Tonnes per Tonnes hour , , , , , , ,34 Time Summary Operating Time Avg Summary Avg time Scaled Tonnes Tonnes Operating time Operational Operating Time Avg DT Summary time Scaled Tonnes Operational DT Planned Operational Operating maintenance Time DT Summary time Planned maintenance Unplanned Planned Operational Operating maintenance DTtime Unplanned maintenance Unscheduled Unplanned Planned Operational time maintenance DT Unscheduled time Idle Unscheduled time Unplanned Planned time maintenance Idle time No Coal Idle Unscheduled time Unplanned time maintenance No Coal time Shifts No wcoal Idle ith Unscheduled time usable data time Shifts w ith usable data Cycle Shifts No Analysis wcoal Idle ith time usable Timedata Cycle Analysis Time Avg Cycle truck Shifts No Analysis cycle wcoal ith time(min) usable Timedata Avg truck cycle time(min) Avg Avg truck Cycle truck Shifts tip time Analysis cycle w(sec) ith time(min) usable Timedata Avg truck tip time (sec) Avg Avg Queue Avg truck Cycle truck time tip (sec) time Analysis cycle (sec) time(min) Time Avg Queue time (sec) Avg Avg Queue Avg truck truck time tip (sec) time cycle (sec) time(min) Avg Avg Queue truck time tip (sec) time (sec) Avg Queue time (sec) Mining Consultancy Services (Pty) Ltd

12 Background Phase 2 Aims: Train all management levels on the meaning and use of each KPI Train all management levels on process based management Develop best practises for the following equipment: Dragline Excavator Truck Bin/Plant Mining Consultancy Services (Pty) Ltd

13 Training Process/Methodology Human Capital Monitor the process element to determine success Process Improvement Resources Environment Implement action plan to achieve target Analyse process element and set target and action plan Mining Consultancy Services (Pty) Ltd

14 Training (KPI s) KPI Definition Comment FirstTip Time between target and actual first truck tipped in the bin Time between target and actual first truck tipped in the bin LastTip Average Tips per Hour TotalNumber of Tips AverageTruck Tip Time Time between target and actual first truck tipped in the bin Number of tips divided by the production hours Total coal tips made into the bin during the shift The average time taken for a truck to discharge into the bin Time between target and actual last truck tipped in the bin Efficiency/ production rate measure Shows tips achieved per shift Shows efficiency of tipping process No Coal Time Time when no coal is seen on the conveyor Shows production opportunity Shift Tonnes Number of tips multiplied by the truck capacity Production measure Scaled Tonnes Measured coal over the conveyor Shows truck fill factor Mining Consultancy Services (Pty) Ltd

15 Training (Process) Mining Consultancy Services (Pty) Ltd

16 Improvement Year on Year Coal 2015 Coal 2016 Variance Jan Feb Mar Apr May Jun Jul Mining Consultancy Services (Pty) Ltd

17 Mining Consultancy Services (Pty) Ltd