joy global - underground mining systems – “pick tip to stockpile”

Pick Tip To Stockpile

Neil Jackson and Colin Parrish

22nd October, 2012

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Introduction

Neil Jackson Business Manager

Conveyor & Development Systems

Colin Parrish Business Manager

Longwall Systems

2

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Integrated Longwall Solutions

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Customer Expectations for Equipment

Safe

Ergonomic

Simple

High MTBF

Low MTTR

Efficient

Supported

• Operable &

Maintainable

• Available

• Productive

• Maximised Output

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Longwall System supply – the Journey…..

Over the last 15 years:

Consolidation of suppliers to the longwall market

Move towards increasingly bundled supply packages

– Project Management and delivery

– Integration of Equipment Interfaces

– Accountability and Risk minimisation

– Availability and Productivity

5

Procurement of individual components

Packaged (PRS, AFC &Shearer)

System Package & Services

Complete System

(Pick tip to Stockpile)

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Longwall System supply – the Journey…..

Project Management

– Co-ordination of multiple suppliers

– Engineering & manufacture processes

– Delivery on-time

System approach

– Integration of equipment interfaces

– Optimise system configuration

– Ensure integrity of the system

– Specification consistency

Accountability and Shared Risk

– System availability & performance

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Longwall System supply – the Journey…..

Integrated supply

Optimised System

– Engineered consistency

–Common specifications

– Integrated approach

Supplier Accountability

– Project Management

– Availability

– Performance

– Timely delivery & start up

Operational support

– Site representative

– System Life Cycle Support

Individual supply

Optimised Components

– Each element maximum

spec or minimum cost as

required

– Manage integration

Mine Accountability

– Suppliers accountable for

own components only

– Need to manage project and

delivery (could contract out)

Operational Support

– Mine personnel

– Manage individual suppliers

7

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Integrated Longwall System – the Next Steps…..

The Complete System

Pick Tip to Stockpile

– Products & Process engineered as a

single system

– Consistent Zero Harm methodology

– Completely integrated solution

– Integrated operation & maintenance

tasks to increase system utilisation

– Consistent training packages and

technical publications

– Optimised reliability & availability

– Single point of accountability

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Mining Equipment Systems

Next stage of the evolution

9

Procurement of individual components

Packaged (PRS, AFC &Shearer)

System Package & Services

Complete System

(Pick tip to Stockpile)

Systems Supplied

for the

complete Process

Operators and Suppliers working collaboratively to

improve operating time across all aspects of the Mining

Process

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

System Design Methodology

Belt Tension vs Time

0.0 8.0 16.0 24.0 32.0 40.00.00

370.00

740.00

1110.00

1480.00

1850.00

Time (Seconds)

Belt Tension (kN)

Rating

Decel

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Production - Opportunity v Actual

Average process output = 1,250 tph

Operating time = 24 X 7 = 168 hrs/week

Potential output = 1,250 X 168 X 52 = 11 MT/annum

Actual average output 2011 = 3.0 MT/annum (29 Longwalls)

Utilisation - time that you intend to operate the longwall

Availability- Utilised time less unscheduled down time

Efficiency - how efficiently it works and is operated when

available

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Longwall Output – Potential to Actual

Utilisation

Efficiency

Availability

Process allows or is elected to be operated

75 Hrs

Process delays 67 Hrs

Potential Output = 11MT

Conveyor equipment operates 69 Hrs

Equipment efficiency when operated

46 Hrs

Operator

Operational ownership

Supplier

Supplier ownership

Planned Maint. 26 Hrs

Equipment Delays 6 Hrs

Longwall equipment operates 63 Hrs

Equipment Delays 6 Hrs

Actual = 3.0MT

System Losses 17 Hrs

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Where could we improve Utilisation?

Identify & eliminate process delays through system design

– Capacity matched system

– Operational matched system

– Mechanical interface/integration

Understand the whole Mining process

– Process optimisation

– Planned simultaneous maintenance tasks

– Easier & Less maintenance demanding equipment

13

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

What’s missing?

Pumps

Electrics

Monorail

Material Re-Supply Safety Inspections

Stone Dusting Services relocation

Structure / Belt removal

Roof Support

Shearer

AFC/BSL

Services

Control & Automation

Belt Conveyors

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Development System

Material Re-Supply Safety Inspections

Stone Dusting Structure / Belt installation

Roadway maintenance

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Where could we improve – Availability?

Understand product limitations – test to failure

Prognostics – identify before failure

Improved reporting – turn data into information

Analysis rules – identify causes and recommend action

Failure mode diagnosis – how not result

Common C&A platforms

16

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Where could we improve – Efficiency?

Real time information

– Analysis rules to identify causes and recommend action

– Monitoring of rates – comparisons to theoretical & previous

Automation at every opportunity

Operator Training

– 3D simulators, common look / feel training aids

– Access to latest equipment information

– Operator performance – transfer of best practice

17

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Smart Services

18

Machine Productivity Technical Information

Portal

Remote Health Monitoring

Reliability Centre

Maintenance Training

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

Summary

Optimised System

Shared Accountability and Risk

Operational Support

Collaborative Approach to Optimise the Process

– Maximised Utilisation

– Maximised Availability

– Maximised Efficiency

19

│ 2012 Oct 22nd │ Pick Tip To Stockpile Australasia

THANK YOU

20