Improving Truck-shovel Matching-nel Kizil and Knights

8/12/2019 Improving Truck-shovel Matching-nel Kizil and Knights

1/20

Improving Truck-Shovel Matching

Dr Mehmet Kizil

Prof Peter Knights

Stephen Nel


2/20

Overview

Shovel-Truck mining system

Standard time definitions

Key Performance Indicators

Case study

Fleet Optimsation

Conclusions


3/20

Aim and objectives

Aim: to optimise a truck and shovel mining system

Objectives: to analyse the data sample;

to assess the current fleet performance levels;

to identify means for improving performance

and reducing downtime; and

to increase the efficiency or effectiveness of the

fleet.


4/20

Truck-Shovel Mining System

Costs 50-60% of the total Mining cost


5/20

Standard Time Definition

Total Calendar Time

(CT)

Scheduled Time

(ST)

Working Time

(WT)

Available Time

(AT)

Operating

Time

(OT)

OperationalDelays

(OD)

Maintenance Time

(MT)

PlannedMaintenance

(PM)

BreakdownMaintenance

(BM)

Idle Time

(IT)

UnscheduledTime

(UT)


6/20

Key Performance Indicators

Productivity: Production (tonnes

or BCM) per operating hour (h)

Utilisation: The percentage ofavailable time that is consumed

by operating time (OT/AT)

Availability: The proportion ofscheduled working time for

which the equipment is available

(ST/CT)


7/20

Factors Influencing Truck-Shovel

Productivity

Several factors can affect the productivity of atruck and shovel fleet, including:

Truck-shovel match and allocation;

Shift operating schedules;

Haul road design and ramp gradients;

Haul road rolling resistance; and

Mix truck sizes in the fleet (Runge Mining, 1993).


8/20

Data and Methodology

Sample period: 01 Nov 200831 Jan 2009

Sample size: 90 Scheduled

working days, 180 shifts

Limitations: Seasonal effects,

FMS outages and machine

module malfunctions

FMS: Real-time monitoring andrecording but no truck

assignment


9/20

Case Study Truck and Shovel

Fleet

Code Machine Model Capacity

EX01 Hydraulic Excavator O&K RH170 22 m3

EX02 Hydraulic Excavator Liebherr R996 34 m3

EX03 Hydraulic Excavator O&K RH120 16.5 m3

EX04 Hydraulic Excavator Liebherr R996 34 m3

SH01 Electric Rope Shovel Marion 301M 35 m3

SH02 Hydraulic Shovel Liebherr R996 34 m3

TR01-07 Rear Dump Truck Komatsu 830E 147 m3

TR08-20 Rear Dump Truck Terex MT4400 144 m3

TR21-23 Rear Dump Truck Cat 785C 78 m3

TR24-26 Rear Dump Truck Cat 789C 105 m3

TR27 Rear Dump Truck Cat 785 78 m3


10/20

Operating Delay Summary for the

Excavator Fleet

0

50

100

150

200

250

300

350

ShiftChange

WaitonTruck Crib

NoOperator

Standby-

NoWorkAvailable

Relocate

Safety

Refueling

Standby-

RepairsComplete

WaitOtherEquipment

WaitDozer-

Operationa

l

AccidentDamage

WaitBlast-

Operationa

l

WorkInstructions

Housekeeping

TotalTime(h)


11/20

Operating Delay Summary for the

Terex MT4400 Truck Fleet

0

200

400

600

800

1,000

1,200

1,400

1,600

1,800

Crib

WaitLoadingUnit

Standby-

NoWorkAvailable

QueueatLoader

NoOperator

ShiftChange

Standby-RepairsComplete

AccidentDamage

WaitOtherEquipment

Safety

Refueling

WaitBlast-Operationa

l

QueueatDump

TravelTo/FromWorkshop

WorkInstructions

TotalT

ime(h)


12/20

Shovel Wait Time


13/20


14/20

Shovel Truck Limited


15/20

Cost Implications of Truck-

Shovel Wait

Fleet Sample PeriodCost

Projected AnnualCost

Wait on Shovel

Caterpillar 785 $128,428 $513,712

Caterpillar 789C $231,104 $924,417

Komatsu 830E $122,273 $489,094Terex MT4400 $422,172 $1,688,691

Subtotal $903,977 $3,615,914

Wait on Truck

Excavator $291,807 $1,167,229

Shovel $77,604 $310,419Subtotal $369,411 $1,477,648

Total $1,273,389 $5,093,562

Assumptions: Shovel= $600/h; Exc= $800/h; Truck= $400/h


16/20

Truck Shovel Assignment

ShovelTruck Fleet

785 789C 830E MT4400

R996 (EX) 3 4 6 6R996 (SH) 3 4 6 6O&K RH120 6 9 12 12O&K R170 5 7 10 10Marion 301M 2 3 4 4

Shovel MF SH Cycle(s)

TR Cycle(s)

TruckNo.

R996 (EX) 1 113 861 7

R996 (SH) 1 186 892 4

O&K RH120 1 175 666 3

O&K RH170 1 177 995 5

Marion 301M 1 108 706 6

Fleet Pass Count Summary

Optimal Truck Number based on MF


17/20

Truck Allocation for Liebherr

R996 on Pre-strip Material

0

5

10

15

20

25

30

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

TruckNumber

Haul Distance (km)

Caterpillar 785 Caterpillar 789C Komatsu 830E Terex MT4400


18/20


19/20

Recommendations

Switch from a semi-automatic to automaticdispatch system;

Reduce truck and shovel wait time through

mix fleet simulation in TALPAC or CAT FPC;

Manage crib break and shift change-over

delays;

Minimise shutdown delays by conducting

opportunity maintenance; and

Conduct a time and motion study to qualify

the FMS data.


20/20

Conclusions

Truck-shovel operations typically have highoperating costs;

Maximise productivity, availability and

utilisation to achieve operational efficienciesand lower cost per tonne;

Optimisation closes the gap between current

and capacity production levels; and One challenge is Truck-Shovel

interdependency.

Improving Truck-shovel Matching-nel Kizil and Knights

Documents

Transcript of Improving Truck-shovel Matching-nel Kizil and Knights