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


Integrated Longwall Solutions


Customer Expectations for Equipment

Safe

Ergonomic

Simple

High MTBF

Low MTTR

Efficient

Supported

• Operable &

Maintainable

• Available

• Productive

• Maximised Output


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)



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



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


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


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


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


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


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


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


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


Development System

Material Re-Supply Safety Inspections

Stone Dusting Structure / Belt installation

Roadway maintenance


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


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


Smart Services

18

Machine Productivity Technical Information

Portal

Remote Health Monitoring

Reliability Centre

Maintenance Training


Summary

Optimised System

Shared Accountability and Risk

Operational Support

Collaborative Approach to Optimise the Process

– Maximised Utilisation

– Maximised Availability

– Maximised Efficiency

19


THANK YOU

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