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,.... (_lSA-Ca-1_83931 UHDE_6_OU_D COAL _IbIWG _82-1695gSECTION P_TA Fir._l _eport (Ketron, £nc.,
i;__: Vayue, Pa.) 151 [: aC AO8/_tF A01 C5C1. 08I::::, Utic 1 a ¢-
...... G3/q3 08825
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-;:_; UNDERGROUND COAL MINING.2:"
..... SECTION DATA
?-.:...._
ill Final Report
:_ September 24, 1981::'7"2..'2;,,
25",.2
PREPARED BY:
"VA
,_ Charles P. Gabrill
Jack T. Urie|
:': REVIEWED BY:
William J. Douglas, Ph.D.
SUBMITTED TO: SUBMITTED BY:
California Institute of KETRON, INC.
!. Technology Hickory Hill Plaza: {i. Jet Propulsion Laboratory 151 South Warner Road
4UOU Oak Grove Drive Wayne, PA 19087,. Pasadena, CA 91103:_: ATTN: David B. Knies:_ ATTN: Mr. John Walsh
,F.?.i"
7-'_ I
1982008580
9950-601
TABLE OF CONTENTS
t-.':
1.0 INTRODUCTION .................................. 1,".
2.0 DATA SOURCES ................................... 2
2.1 KETRON Database ......................... 2_ 2.2 Jim Walter Resources, Inc. Database ..... 4
; 2.3 Supplemental Questionnaires ............. 4i::
3.0 PROCESSING OF KETRON PATABASE ................. 8
1.... 3 1 Transformations 8• eo ooo oo el ooo oe ooee eoooooo o
3.2 Processing Procedure .................... 9 i03.3 Overlapping and Insufficient Data ....... 14
::::
4.0 RESULTS ....................................... 17
4.1 KETRON Database ......................... 17F::" 4.2 Processing of JWR Database .............. 17
4.3 Survey Results .......................... 22,:--
S.0 Comparison to J.J. Davis Report Data .......... 28
29..... 6 0 References• qDo o oe o oo (,oooo e e • ooo oo a, eo • Io oe I aomeo I
A*.::,.2:2
:::: APPENDIX A Transformation of KETRON Activity Data to
JPL Machine-Worker-Function Categories -;.::"
,. APPENDIX B COALS Reports - Raw Data
APPENDIX C JWR Time Study Data
' APPENDIX D J.J. Davis Time Study Results
_ i: APPENDIX E Sample Questionnaire
i
4.
ifll. ii
:E"I:::
_411111W,,,.- ..............
] 982008580-002
'-_'"_ 9950-601
LIST OF FIGURES
'_ Figure_.-. Number Title Page
i 3-I Activity - Function Allocation File .......... I0
3-2 Activity - Equipment Cross-Reference File .... Ii
[ ""
3-3 Activity - Personnel Cross-Reference File .... 12
3 4 COAL5 Report File Format 13oeeoeeQeoooeomoeoeoee
• :!
; iii
3
1982008580-003
":" 9o¢0-601 ]_"": L-. t
_ •
"; ::..-
LIST OF TABLES
1114...." Number Title Page
.:::.
_- 2-1 Total Shifts and Report Types for KETRON 3:::.... Source Data ...............................
_---. 2-2 Section Parameters for KETRON Source Data ... 5_.'-:'.
_i_i 2-3 Continuous Miner Transformations (JWR Data-
; base ) ..................................... 6f.-"
.... 2-4 Roof Bolter Transformations (JWR Database) .. 7
3-1 Data Sources for Equipment Categories ....... 15
3-2 Data Sources for Personnel Categories ....... 16L_
4-1 Equipment Matrix - KETRON Composite Data .... 18
?????_ 4-2 Personnel Matrix - KETRON Composite Data .... 19
4-3 Equipment Matrix - JWR Composite Data ....... 20:222
i"_ 4-4 Personnel Matrix - JWR Composite Data ....... 21
4-5 Personnel Matrix - KETRON Survey Results .... 23
4-6 Questionnaire Results - Mechanic ............. 25
r;_ 4-7 Questionnaire Results - Bratticeman .......... 25
4-8 Questionnaire Results - Utility Man .......... 26
!i 5-I Comparison of Time Study Results forContinuous Miner ........................... 28
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1982008580-004
9950-601
.. 1.0 INTRODUCTION
:_ The objective of this contract is to provide the JetPropulsion Laboratory (JPL) with a set of tables which displaythe allocation of time for ten personnel and eight pieces of
i--: underground coal mining equi ment to ten function categories.These tables are presented in this report as Table 4-1 andTable 4-2. Data from 125 full shift time studies contained in
the KETRON database was util_zed as the primary source data.
..>.: KETRON activity and delay codes were mapped onto JPL equipment,
:: personnel and function categories. Computer processing was then
performed co aggregate the shift level data and generate the
_ matrices. Additionally, documented time study data from Jim: Walter Resc_rces, Inc. (JWR) was analyzed and used to supplement
the KETRON database.
!_ Section 2 of this report describes the source data in-
cludi'g the number of shifts and presents specific parametersof the mines from which this data was extracted. Section 4
_ presents the result of the data processing including the re-
: quired JPL matrices. Section 5 presents a brief comparisonto a time study analysis of continuous mining systems performed
u_ by J.J. Davis Associates. [_*
Section 3 describes the procedures used for processing
the source data.
.:.!{
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1" Number in brackets [] refer to references in Section 5.
_ -1-
P
1982008580-005
-_ 2.0 DATA SOURCES
:_ 2.1 KETRON Database
Over the past several years, KETRON has developed an
_ extensive data base of time study information gathered during_ the course of numerous industrial engineering studies for both
_::: government and industry. These studies required the on-site
collection of mine activity data by experienced mining personnel.
iill_ Observers located at the miner, dump and roof bol_er were able
-:_: to record the begin and end times of specific events for thecontinuous miner, shuttle cars ana root bolter for an entire
shift. This recorded data was subsequently coded and processed
through a series of computer programs (COALI-5) which output2".2
.... activity and delay times for equipment at each location for eachshift.
Output from the COALI-5 programs for the continuous minerincludes a statistical report which presents the total time for
• each activity and delay as well as the trequency of occurrence,
_ the mean, standard deviation and range. Similar reports for the
aump and roof bolter were produced. These reports provide the !_ source data for this study.
L
Section 3 describes the actual processing procedures used
on this data. Essentially, the functional allocations for the_ continuous miner, the miner operator and miner helper are based i
1 on data from the COAL5 continuous miner report. Allocations forthe shuttle cars and shuttle car operators are based on data fromthe COAL5 continuous miner and dump _eports. The dump report
provides shuttle car discharge times and delays while th_ contin-uous miner report provides shuttle car loading times. Roof bolt-
er, roof bolter operator and roof bolter operator helper alloca-tions are based entirely on the roof bolter reports.
The results presented in the tables in Section 4 represent !
an aggregation of data contained in four groups of data sets 1representing different time study projects. These projects in-clude:
o Freeman United Coal Company - Two mines
located in Southern Illinois [2]
o Appalachian Regional Commission - South-
Western Pennsylvania Mine [_
o Industrial Engineering Study of Conventional
[ Coal Mining Systems - II mines located
: throughout the U.S. [4]
: Table 2-1 displays the file types and total number of shifts_ , tot each of the above projects which were used in creating the
¢ •
_ . -2-
1982008580-006
[:i_i_ TABLE 2-1
Total Shifts and Report Types for KETRON Source Data{h::.5
Mine Source Re,port Types Total Shiftst"::
!.Freeman United - A Continuous Miner 17
Dump 17::.::. mm_4
:._:. Freeman United - B Continuous Miner i0.... Dump i0 i
:- Appalachian Regional Continuous Miner 40 iI
Commission - SW PA !.": IE Study of Roof Bolter 31 -'"_ I'::I Conventional Systems-
Various U.S. Mines,, . , , , ,
. [:
-*-_ TOTAL 125
i*
] 982008580-007
_::::
matrices. Roof bolter data acquired during the "IE Study of
Conventional Systems" is included, since the activities of the
i_ii[ roof bolter in conventional systems are essentially the same as_ those in continuous mining systems.
_:: The data files from each mine source are for multipleii!_ sections in one or more mines. Table 2-2 describes the locations,
seam height, roof quality and floor quality for each mine source
which has been included in the development of the matrices._.:
_::_
.... Appendix B contains the COAL5 reports which served asthe raw data source tot the construct_:, ot the matrices.
ij_:_ 2.2 Jim Walter Resources Database
Time study data for the continuous miner and roof bolter
were gathered and documented by industrial engineers of Jim!_ Walter Resources Inc., (JWR) for several of their mines. For
this report, three sets of data were analyzed: 1980 continuous_ miner data for six shifts; 1979 continuous miner data; and 1978""v
_ roof Polter data tot thirty-three shifts. Raw data tables arepresented in Appendix C. Times appearing on these tables were
=_ normalized by JWR on a per shift basis. Each JWR time element•: was converted to the appropriate JPL function classification
: based upon the judgment of KETRON mining personnel. T_esetrans£ormations are presente_ in Tables 2-3 and 2-4.
:_i 2.3 Supplemental Questionnaires
_ The data sources described in the previous two sectionswere adequate for providing data on those personnel who are
directly related to a particular piece of mining equipment.Other personnel have no such direct allocation, i.e., the sec-
_ tion foreman, mechanic, bratticeman, and utility man or helper.
- To complete the JPL equipment/personnel matrlces, it was neces-
sary to develop a questionnaire on each of these job functions,: and submit this questionnaire to experienced mining personnel.
The questionnaire was submitted to JPL and approved for use in aletter dated April 2, 1980. 5 A sample of this questionnaire
appears in Appendix R.
--4--{
".,W
1982008580-008
9950-601
.... TABLE 2-2
_../. Section Parameters for KETRON Source DataL.i
:.... ! I I I':-:_ SZCTION SEAM ROOF FLOOR__ PROJECT NUMBER LOCATION HEIGHT qUAL!,TY qUALX_"f
Freeman All IL 96" Good Hard & Dry::. United - A Se=tions (Shale)
:": Freemen All IL 96" Good HaL'd & DryUnited - B Sections (Shale)
'::: Appalachian All PA 51" Fair Soft & Wet_:- Regional Com- Sections (Soft ,:"" mission Shale)
{._? Zndustrlal 1 OH 58" Pair Hard & Dry:_:: Engineering (Shale-::_1 Study - Con- Bastard
ventional Lime)Coal Mining
_:_ SyStems 2 OH 42=-44" Excellent Hard a Dry_ (Limestone)
3 OH 70" Excellent Hard & Dry:. (Limestone)
:'" 4 WVA 60" Good Rolling I(Shale) Some Standing
Water
-:: S WVA 84" Pair Hard a Dry,: (Clayey
Shale)
"" 6 ALl 108" Good HeavingC:.. (Shale)
7 OB 60" Fair Soft a wet
::_ (SandyShale &Sandstone)
8 HVA 55" Good Hard 6 Dry(Shale)
9 HYA 70" Average Hard & Dry(Shale)
i lO ALA 36" Good Excellent(sandy
; shale)
11 ALl 30" Good [xcellent, (sandy' shale)
; . 1Leo
i ..
U •.--- . ........ ii---
1982008580-009
TABLE 2-3
_::__Y:_ Continuous Miner Transformations
_i!i JWR Element JPL Function_52° ....
_ Travel In Man Systems
li!!Travel Out Man Systems
!_} Cutting and Loading Coal Cuttin_
Cleaning By Miner Man Systems
!_: Cutting W/O Car Coal Cutting
_ Switch With Car Section Haulage
Switch No Car Section Haulage
_;:_ Car Change (Residual) Section Haulage
Place Change Tram Coal Cutting
_:}! Place Change Handle Cable Coal Cutting
In Place Handle Cable Coal Cutting
_:;; In Place Service Duties Maintenance
- Mine Health and Safety Delay Man Systems
:2.2
.... Mechanical Delay Maintenance :
"/_::.._: Coordination Delay Coal Cutting
Condition Delay Coal Cutting
•_. Gassed Out Man Systems. A, ., .
:,:;:
-(f
_-:"
r':.
] 982008580-0] 0
! 9950-601 _,2:
TABLE 2-4
i_ Roof Bolter Transformations_.
i:_ JWR Element JPL Element
i i'v |
_"__/_ Total Travel Time Man Systems
Start of Shift Inspection Man Systems[,,:
i_ Power, Belts, Etc. Allocated to electrical,
main haulage and miner
: Cable splices Roof Support
Instruments Roof Support!:
.... Federal Inspection Time Man Systems
_ Cable Handling Roof Support
Curtain Delay Ventilation
Gas Check Man Systems
Tram Time Roof Support
Bolting Time Roof Support
_ Other Cyclic Delays Roof Support
Other Impositions Roof Support
i:
&,,
1982008580-011
I_: 9°_0-6"31
3.0 PROCESSING OF KETRON DATABASE
; The allocation of KETRON activities to JPL function,_:::j
equipment and personnel categories is the most critical step
:_; in the processing of _ur time-study data base. This section_;_ presents the transformations which have thus far been defined,
:;! discusses the data processing effort which was performed and
provides an indication of which elements of the required JPL
,ii_i matrices must be estimated using survey results. Section 3.1:_.._: describes the transformations and Section 3.2 describes the data
processing steps. Overlapping and unsufficient data issues are
-_ discussed in Section 3. Appendix A contain the tables which_ define the transformations.
3.1 Transformations
_ Each of _he KETRON activities and delays were obtained
from KETRON's COAL series master event and delay lists. These
ˆcontain all activities which app-_r on the COAL5 reports.i_!i The COAL5 reports contain the elapsed time for each activity of-- a specific mining operation during a given shift. For each re-
port type (Continuous Miner, Dump, Roof-Bolter), a set of tables
!!_ were prepared which define the fraction of each K_TRON activity
::::_ and delay code which is to be allocated to JPL functions. Addi-
tional tables define the equipment and personnel assignments
_ for each activity. The transformations defined by these tables
_:_ are based upon judgments by experienced personnel who weredirectly involved in gathering the time study data.
: Exhibits IA to IC of Appendix A display the allocation
: of KETRON activity and delay codes for each file type. Entries i
in these tables indicate the fraction of activity time which was_- allocated to a function category. The sum of the fractions for I
!; each activity must equal one. As can be seen throughout the Iten charts of Exhibit I, the great majority of the KETRON activity iand delay codes fall entirely under one JPL activity/function
designation.
Exhibits 2A to 2C of Appendix A present the equipment as-
signments. Exhibits 3A to 3C display the personnel assignments.
:! An entry of "i" in these tables indicates that this piece ofequipment or person is associated with a specific activity or
delay code. These assignments are based, primarily, upon the
i; file type from which these activities (delays) are recorded and: directly reflec_ which pieces of equipment and men were observed.
For example, activities and delays from the continuous miner
i _ file are primarily assigned to the continuous miner since data
! _/ contained on this report was recorded at the section face while
observing the miner.
,(| .'
; -8-
_ !_
1982008580-012
' 9950-601';...
The above transformations were utillzed as follows: time
!:{ _or a specific activity (delay) which is read from the COAL5ii_ reports were assigned to the appropriate equipment and personnel
and allocated over f_1_ctions as defined by Exhibits IA to IC. ,
_ 3.2 PROCESSING
Data from the transformation tables were keypunched and
_ the following files created:
o Activity - Function Allocation File
.... o Activity - Equipment Cross Reference File
..:::
O Activity - Personnel Cross Reference File
Figures 3-1 to 3-3 present the data elements contained in
=:: each file. The format of each file is also shown for programming
: purposes. Separate files were created for each COAL5 report
:": type. )
_:_ Data fKom the COAL5 reports (Appendix B) were keypunchedTL
k. according to the format shown in Figure 3-4. A computer program
was developed which input the keypunched data and aggregated the:. activity time for each KETRON activity and delay code. Using
::; thu cross-reference files, this program then allocated the ag---,[
gregate times, to the appropriate JPL function, equipment andpersonnel categories. The resulting output froln this program
: included:
o _ table containing for each KETRON activity/
_ oelay code the following:
-- Total frequency-- Total time-- Mean time
-- Average Standard deviation
o Total time studied
o Total shifts studied
o JPL equipment and personnel matrices contain-
" ing actual times instead of percentages.
A separate set of outputs were generated _or each of the four
time study projects.
(t" .
--9--
1982008580-013
1 9950"601 'l
'_-'[ DESCRIPTION COLUMNS FORMAT
Report Type: 1 I1 '
_.:f.'.. i - Continuous Miner
:::_ 2 - Dump": 3 - Roof bolter
Activity/Delay Indicator: 3 Ii
_::_:....:. 0 - Activity
..... 1 - Delay
;-....;
-_:- Activity or Delay Code 4-5 I2
,!i!_..:_:
ii{i Fractional Allocation 11-60 10F5.2for each function
--:::x:"
.....
• ::[
:i'.i: FIGURE 3-1
_:: ACTIVITY - FUNCTION ALLOCATION FILE
-i0-
1982008580-014
! 9950-601).
i ""
t
[_ DESCRIPTION COLUMNS FORMAT,::::
Report Type: I IIl:u:
[:-:." 1 - Continuous Miner
2 - Dump3 - Roof bolter
"-.:'i
Activity/Delay Indicator 3 II
":ii 0 - Activity
1 - Delayi_
Activity or Delay Code 4-5 I2
_222":
•:.:i. Equipment - Assignment Ccde 11-20 8If
-::: 0 - Equipment is not assigned
i!i_ to activity co----de..-;:
1 - Equipment is assigned to
i'_". this activity code
FIGURE 3-2%7'.
ACTIVITY - EQUIPMENT CROSS REFERENCE FILE
f
{,....
1982008580-015
, 9950-601 f
3 DESCRIPTION COLUMNS FOR.MAT '_I;.Report Type: 1 II i.
,! {1 - Continuous Miner
' 2 - Dump i'3 - Roof bolter
J
Activity/Delay Indicator 3 II
0 - Activity
' 1 - Delay
Activity or Delay Code 4-5 I2
Personnel - Assignment Code 11-20 10If
0 - Person is not assigned
to activity code
1 - Person is assigned to
this activity code
I
FIGURE 3-3
ACTIVITY - PERSONNEL CROSS REFERENCE FILE !
(
-12-
-- ! _ - _ .... _ .... _ ..... _ ..... q
1982008580-016
I.... 9950-601
[ .:
i..
I{ DESCRIPTION COLUMNS FORMATit
Project Code: 1-3 A3
I
! i ARC - ARC projectFU1 - Freeman United - Phase IFU2 - Freeman United - Phase 2
i:_ IEC - Conventional IE Study{,..
Sequence Number 5-6 I2
Two digit sequentiel: Number for set of data
Report Type 8 II
_: 1 - Miner'
2 - Dump3 - Roof Bolter
Activity/Delay Code i0-II I2
i!Availability Code 13 II
Indicates overlapping: activity or delay
Number of Shifts included 15-16 I2-- for this set of data
Frequency 18-20 I3
Total Time 22-28 F7.0
Standard Deviation 30-36 F7.0
..\.
" FIGURE 3-4
COAL5 Report File Format
(°
I "
-13-
] 982008580-0] 7
_.._ 9950-601
From each set of computer output, percentages were man-
ually calculated for each cell of the JPL matrices, The percent-_.:{ ages were weighted appropriately for each time study project and
_i averaged across all projects. ° The results are the matrices pre-sented in Tables 4-1 and 4-2.
_,_ 3.3 Overlapping and Insufficient Data
3.3.1 Overlapping Data
_:_ A potential problem with the allocation procedure is
double counting. Since identical activities occur on different
; report types for the same shift, one must be careful not to as-_: sign the same equipment or personnel type more than once to
these activities. In other words, if "mechanic" is assigned to
activity "man trip in" on the continuous miner report, he cannot-_ also be assigned to this activity on the Dump report. If he was,
i the mechanic's man trip time would be counted twice for a given
shift. By judiciously assigning men and equipment to specific
:: report types, this has been avoided.
_3.3.2 Insufficient Data
::_ For certain equipment and personnel, there is a lack ofi.:
-- observed time-study data. Table 3-i indicates those pieces of
equipment for which sufficient data exists and those for which
survey information was required. For pieces of equipment for4 which time allocations are based upon actual time study data,
the source of this data is indicated. Table 3-2 presents similar
information for each personnel category.
-14-
1982008580-018
I 9950-601|....
: TABLE 3-1
i_i!" Data ._ources for Equipment Categories
,.-,
_;_ EQUIPMENT TYPE SOURCE OF DATA FILE TYPE.,:"
Continuous Miner Time Study Continuous miner COAL4:k file,'.V
Shuttle Car #I Time Study Dump COAL4, Contin-_ uous Miner COAL4
,.,:,
Shuttle Car #2 Time Study Dump COAL4, Contin-uous Miner COAL4
Roof Bolter Time Study Roof Bolter COAL4
Section Belt Time Study Dump COAL4
Main Belt Time Study Dump COAL4
,..l:
: Rock Duster Survey
Electricals in Survey:_: Section• j
f
, -15-
h ........ ]m_
1982008580-019
E
" TABLE 3-2
,4 Data Sources for Personnel Categories
L_
{:: PERSONNEL SOURCE OF DATA FILE TYPE
::_ Continuous Miner Time Study Continuous Miner COAL4::i[ Operator
Continuous Miner Time Study Continuous Miner COAL4
!.. Operator's Helper
Shuttle Car Operator Time Study Dump COAL4, Continuous#I Miner COAL4
Shuttle Car Operator Time Study Dump COAL4, Continuous#2 Miner COAL4
!: Roof Bolter Operator Time Study Roof Bolter COAL4 I
.... Roof Bolter Operator's Time Study Roof Bolter COAL4• Helper
Sectlon Foreman Time Study, Continuous Miner COAL4
Survey
Mechanic Survey
: Bra':t iceman Survey
Utility Man Survey
{
{
(
-16-
t
1982008580-020
4.0 R_ESULTS
ii Results for the JPL were obtained from three sources:
!iO KETRON Database i,
_ o Jim Walter Resources
o Survey Questionnaire:.i
_i:_ Each of these is summarized in this section.
4.1 KETRON Database
Table 4-1 presents the JPL equipment matrix. The al-
- locations on this table represent a composite of all data used=_ for this study and contained in the KETRON data base. Time
study data for the rock duster is not available, therefore,
percent allocations are based entirely upon survey data. The' section belt, main belt, and section electricals are not observed
_: directly during the time studies. However, delays and man system
operations for these pieces of equipment were reo,rded by theobserver at the dump. The difference of the recorded time and
total shift time is the time that the equipment was in normal{.:
operation (i.e., section belt in section haulage, main belt inmain haulage and section electricals in electricals function).
-4 There is no distinction is made between shuttle car i
(standard) and shuttle car 2 (off-standard) in the allocation
of times to functions. While there may be slight variations be-
tween these two machines at the shift level, the differences for I
the aggregated data are not significant.
Table 4-2 provides the allocations of personnel to func-
" tion categories. Although the time studies are designed to
track the activities of equipment, it is the experience of the I
_: observers that the allocations for the operators are identicalto that of their respective pieces of equipment during normal
operations. Occasional activities for the section foreman, mech-
anic, bratticeman and utility man were recorded duriLg the
tim_ studies for specific operations. However, this data is
incomplete and therefore survey data was utilized.
4.2 Processin@ of JWR Data
Data from published time studies made available to KETRON
by JWR was utilized to create the JPL equipment and personnelmatrices presented in Tables 4-3 and 4-4. Time elements were
:- a_signed the appropriate JPL function and percent allocations
for each function were calculated. Only data pertaining to the
(
-17-
1982008580-021
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1982008580-025
!
continuous miner and roof bolter are available; therefore, times
_I were allocateo only for these pieces of equipment and their! _ operators.
The tables appear to indicate that the time allocations
i_ are consistent with those based on the KETRON data. One signi-
:_ ficant difference is the large percentage of time allocated tomaintenance for the continuous miner on the JWR data matrix.
This is a result of assigning the JWR time elements of "Mechan-:_,_i ical Delay" and "In Place Service Duties" to the maintenance
=: functions. A more detailed breakdown ot these elements would
likely indicate unscheduled delays due to shuttle car break-
downs, section belt failure, ventilation repairs, etc. These
:.:_: delays would then be allocated to such functions as sectionhaulage and ventilation.
: 4.3 Questionnaire Results
The final results of the survey questionnaire are in-
i_i cluded in the two (Tables 4-1 and 4-2). A total of twenty in-:X dustry personnel, compiled from a list of KETRON staff contacts,
agreed to provide the necessary information. These individuals
ranged in position from Mining Industrial Engineer to OperationsVice President, although all of them had, at one time, been
directly associated with mine production work either as a section
_: foreman, underground laborer, or production analyst..?
A total of twelve questionnaires were ultimately returned
to KETRON for analysis. It is not known why the other indivi-duals chose not to respond. Due to time constraints, a decision
: was made to proceed with the tabulation and analysis without con-
tacting additional personnel or "prompting" the non-respondents.
Tables 4-5 through 4-8 display a summary of the ques-
--_ tionnaire response.
As shown in Tables 4-1 and 4-2, the foreman is said to
spend most of his time in the man systems function, which is
mainly the mantrip and various safety-related tasks. Approxi-mately one-third of the shift is spent in coal cutting activities,
which is mainly supervising the miner operaticns.
The largest portion (45.5 percent) of the mechanic's time
is allocated to the maintenance function, as expected. The
percentages llstea for the coal cutting and section haulage
functions represent the mechanic relieving the various equipment
! operators for lunch breaks. The 21 percent figure listed forthe "other" category represents idle time. It was decided to
place this idle time in this category rather than one of the
other categories so as not to distort the figures in the spec-
iEic job function type.
-22-
1982008580-026
f
"::" 9950-60 1
;-o
i.i_ _':,_,,._.4-5_.._
Questionnaire Results - Foreman
".. Time P_riods 1 Percentage of Shtftz 6,2S
Nomlizattons
•. Activity Job runcti _n Time Shift2.?- Categor_ Period
. Run races Man Systems 0.46 0.0288
" Give Work Man Systems 0.2S 0.0IS6Assignments
• Supervise Cut Coal Cutting 0.IS 0.009_Preparaticn
Check [quipment MainteL_ance 0.07 0,0044
_ " R_port to Mine Other o 02 0.0019-:-_ Manager
_.: energize Equipment Electrical 0.02 0.0013 r
L_ Safety Talk Man Systems 0.02 0.0013
Time Periods 2 Percentage of Shift: 37.5.}
gormalizations
Activity Job Function Time ShiftCategory Period
_. Supervise Subsequent Coal Cuttin_ 0.23 0.0563-. Cut Preparation
Equipment�Machine Maintenance 0.0i 0.03_0Checks
Inspection of General 0.02 0.007SWork
Inspection of Supplies Man Systems 0.09 0.0330
lan Subsequent Cuts Co411 Cutting 0.04 0.01S0
Methane Checks Man Systems 0.11 0.0675
OOser_e Crews 50/50 Coal Cutting/ 0.31 0.116__=of Support
_aintain Ventilation Ventilation 0.04 0.0150
Other Other 0.01 0,035
-23-
, a7
1982008580-027
9 9 50 - 6 0 1TABLE 4-5 (Cont'd.)
6"'i
_: Questionnaire Results - Foremanu _.
Time Period: 3 Percentage of Shift: 37.5
i_ Normalizations
:.... Activity Job Function Time Shift
_ Categcq Period
Observe Face Opec- Coal Cutting U.ZZ 0.04505::_ atlons
!3_ Observ_ Bolter F_of Support 0.03 0.0113
Walk Belt Line Main Haulage 0.08 0.0300_
_ Write Maintenance Maintenance 0.04 0.0150:::: List
Routine Section Man Systems 0.03 0.0113
[_ CheckL •
_-A Check Supplies Man Systems 0.03 0.0113
_? Supervise Subse- Coal Cutting 0.15 0.0488..... quent Cut Prep-
__ aration
Equipment/Machine Malntenance 0.05 0.0188
_::_ Checks
_5! Inspection of Gen'l. Other 0.02 0.0075
Work
c:::_:_: Inspection of Supplies Man Systems 0.06 0.0225
_ Plan Subsequent Coal Cutting 0.04 0.0150Checks
i_+ Methane Checks Man Systms 0.13 0.0488
Observe Crews 50/50 Coal Cutting/ 0.18 0.0675ROOf Support
_._\ Maintain Ventila- Ventilation 0.04 0.0150
_-5_ tion
Other Other 0.02 0.0075
Time Period: 4 Percentage Of Shift: 6.25
_._' Final Gas Checks Man Systems 0.27 0.0169
Supervlze Section Maintenance 0.22 0.0138
... Preparation
L[
:: Call Out Report Other 0.29 0.0181
: Check Supplies Man Systema 0.06 0.0038
: _eenerg_zeEquip- Electrical 0.06 0.0038"::" sent
Check Equipment Loca- Other 0.I0 0.0063
_:_ riCh/Condition
.._(. Time Period: Mantrip In/Out Percentage of Shift 12.5[ • All of Mantrip Ti 'ePlaced in Man Systems Job Function Category.t '"b..
-24-
] g82008580-028
9950-601
TABLE 4-6
Questionndirc Results - H_chanic
Percentage o_ Shi_t Spent Repairing Equipment, 52.0, Percentage of Shift on Mantrlp: 12.5
Normalizatione
Activity Job function Time ShirtCategory Ptriod
REPAIR TIME MAINTENANCE 0.5200 0.4550
NON-REPAIR TIME
Rl_nning Equipment 50/50 Coal Cuttlnq/ 0.2160 0.1890Section Haulage
Deadwork O_her 0. 2400 0. 2100
Ventilation" Ventilation 0.0048 0.0042
Supplies Man Sy.t_me 0.0144 0.0_26 I
Rock Dust Rock Ousting 0.0048 0.0042i
TABLE 4-7
Questionnaire Results - Bratticeman
percentago of Shift Spent on Non-ventilatlon Work: 40.0Percentage of Shift on Mantrlp: 1:.5
Normalizations
Activity Job function Time Shift
Category Period II
VENTILATION TIME Ventilation 0.6000 0.5250 I_
INON-VENTILATION TIME
Shovel Ribs Other 0.0480 0.0420
kelp Solters ROOf Support 0.1600 0.1400
Rock Duet Rock Oustinq 0.0880 0.0770
Assist Mechanic _alntenance 0.0720 0.0175
Run Shuttle Car Section qaulaqe 0.0200 0.0175
Clean Belts _ain Haulage 0.0120 0.010$
-25-
p .... .
1982008580-029
_ 9950-601
TABLE 4-8
"_ Questionnaire Results - Utility Man
' Percentage of Shift on Mantrip: 12.5
Normalizations
: Activity Job Function Time Shift
Category Period
Help Bratticeman Ventilation 0.2000 0.1750
Shovel Belt Main Haulage 0.1330 0.1164
Run Equipmen_ Section Haulage 0.1500 0.1313
Supplies Man Systems 0.2220 0.0726
Assist Mechanic Maintenance 0.0720 0.0630
Rock Dust Rock Dusting 0.0720 0.0630
,_o Miscellaneous Other 0.1400 0.1225
t
(
r
-26-
1982008580-030
p_
I 9950-601
Responses for the utility man and the brattice man tendedto be inconsistent. These two job functions tend to be less pre-
i_ cise in nature; that is, there is no set job responsibility for_.:: either personnel type, although the brattice man's ma_n responsi-
bility is to maintain section ventilation.
_ The questionnaire approach used in this study was con-sidered to be successful. The 60% response rate was not unex-
pected, and is considered to be reasonable, based on previous
!_{! similar survey efforts. Job function results for the section!i_ foreman and the mechanic are consistent with KETRON's first-hand
experience, and there was a high degree of agreement among the
.... respondents for these two personnel types. For the last two
_i face personnel, however, it is doubtful that any two sets of
responses would be consistent, given the nature of the jobs.
Similarly, the non-face personnel row tended to be mine-specific, __ and a wide response variation was received.
il
e
.(..o
-27- "
i
1982008580-031
9950-o01."V
: 5.0 COMPARISONS TO J.J. DAVIS REPORT DATA
_:_ Under contract to the U.S. Bureau of Mines, J.J. Davis
!, Associates performed a detailed industrial engineering study ofcontinuous mining systems. 1 The scope of work for this pro
ject included time studies for the continuous miner, haulagevehicles and the roof bolter. This data is summarized in tables
extracted from the report and presented in Appendix D.
It is difficult to make comparisons of the percentages
:-_ displayed in these tables to those in Tables 4-1 and 4-2 due to
the large percentage of time in the general categories of "D_xayand "Idle". _'or example, most of the idle time for a roof bolter
LI is caused by waiting for the continuous miner; therefore, thistime would be allocated to coal cutting, the KETRON ti_._ study
system is designed to provide a detailed breakdown of machine
_ _clays. This permits allocation of these oelays to the JPLfLnction categories. However, the J.J. Davis study was concerned
only with the actual production time for a piece of equipment,
therefore, all delay times are grouped into one time element.
TABLE 5-1.o
Comparison of Time Study Results for Continuous Miner
KETRON J.J. DAVIS
Production Time 26% 27%
Non-Production Time 74% 73%
(Includes all delays)
As described in Section 3, the processing of KETRON data
yields the total time spent for each KETRON actlvity and delaycode for each time-study project. From this, we were able to 1
aggregate the times spent on productlon-related activities forthe continuous miner. Dividing by total shifts time provided an
appropriate percentage of time the miner was involved in produc-
tion. This figure was then compared to the J. J. Davis percentage.
The result appears in Table 5-I. Note that this is strictly a
rough comparison since it is not evident which activities are
considered productlon-related in the J. J. Davis study.
-28-
1982008580-032
9950-601,-:_
6.0 REFERENCES
I. J.J. Davis Associates, Industrial Engineering Study
:_: of Continuous Mining Systems, Final Report, August:_ 8, 1977, USBM Contract J0357096."'V
_ : 2. KETRON, INC., Mine Productivity Study - Phase II Re-
_i_ port, Final Report, January, 1979, Freeman UnitedCoal Mining Company.
: 3. KETRON, INC., A Three Year Organization@l Develo P-
' ment Action Research Demonstration Project In An
__ Under_round Coal Mine, Draft Final Report, July, ,1980, The Appalachian Regional Commission.
4. KETRON, INC., Industrial [email protected] of- Underground Mining Eguipment, Final Report, July,
1976, USBM Contract J0155203.
5. JPL, April 2, 198!, correspondence, JPL Contract
955966, subject: Comments on Time Study SurveyForm.
::
(
, -29-
1982008580-033
:-,'" 9950-601 1_|
il,
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..*°.
i:i-v:::
::: APPENDIX A
i.: Mapping of KETRON Activities and Delays to
.- JPL Function, Equipment and Personnel Categories
_i Ii:.:Z Exhibit 1 - KETRON Activities/Delays vs
JPL Job Function Categories
T:_ Exhibit 2 - KETRON Activities/Delays
vs JPL Equipment Categories
i-;
Exhibit 3 - KETRON Activities/Delays
... vs JPL Personnel Categories
(
1982008580-034
9950-601
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KETRON Activities/l_lays-.--
•:. VS.
:- JPL Job Function Categories5-:%
4".
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1982008580-035
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I 9950-601
_:._ EXHIBIT 2 !,
KETRON Activities/Delays i
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"t'::.:
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1982008580-046
1982008580-047
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i_ APPENDIX C
JWR Time Study Data
_...
°°_
°.H
°_
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L..'.
q982008580-q 30
AUG. & SEPT. 1979 STUDIES
T
::'::
:.:::.... ELEMENT MII_Ir'Es / b'HIFI'
CUTTING AND LOADING 68.23
..
:'_ CLEANING BY MINER 2.39
:-..- CUTTING W/O CAR. 10.97
:-.-_
"'" SWITCH WITtI CAR 10.81
ii_ SWITCH NO CAR 13.43:---:
CAR CHANCE (RESIDUAL) 58.59:'.:.
:
::._ PLACE CI_NGE TRAM 19.58
PLACE CHANGE HANDLE CABLE 13.42
_: PLACE CHANGE SERVICE DUTIES 6.13
.:, IN PLACE HANDLE CABLE 3.76
IN PLACE SERVICE DUTIES 34.36----
MINE HEALTH AND SAFETY DELAY 23.01
MECHANICAL DELAY 93.44
COORDINATION DELAY 28.65
CONDITION DELAY 14.32
GASSED OUT 1.93
TRAV1_ IN 39.42
'rX_kVELour 37,38i TOTAL 479.82
" " - _lrll '
1982008580-131
995o-6oii-I-
.'::'. CIIANGE IN PRODUCTIVITY iL= !_..:: BOLTER
!:ii_:_, SECTIONS 3,4,7,8,10
i':'-
_/::: Total Time -Portal to Portal 480.00 Hfn/U.S. Mih/U.S.
Total Travel Time 63.70 Min/U.S. " Min/U.S.
!_:.,.:-: Check for Smoking Articles 0 Hin/U.S. Hin/U.S.
i::_ Ventila tlon Delay 0 Min/U. S. Min/U. S.
Start of Shift Inspection . 10.54 MIn/U.S. Min/U.S.
_i_ Power, Belts, etc. 157.70 Min/U.S. Min/U.S.._!!:T: Ins tall flangers 0 Min/U. S. " Min/U. S.
Gross Time At Face ./._MIn/U.S, Min/U.S.
;: Cable Spllces 1,21 Min. .25 Z ____._.}Lin. Z
i:_i: Instruments 2.83 Min. • 59 % __._ Hin. %
"::: Illumination __Q__Min. O Z }Àin. %Other Imposltion(non-cycle) 0 Min. 0 Z Min. g
.... Bolter Availability 51.68 Z- .84 Z = _ 50.84 Z Min. Z - ______g_:i'.- _et Time At Face 244.02 Min/U.S. Min/U.S.
•23 Z Federal Inspection Time .56 Min/U. S. Min/O.S.
:a Adjusted Net Time At Face 243.46 Min/U.S. Min/U.S.
:::::: Cable Handling .8_ Min/Place Min/Place:j:.-..
Curtain Delay 2.42 Min/Pl_ce Mln/Place
=_ Gas Check .28 Hin/Place Hin/Place
_:: Tram Time (bolter) 4.39 Min/Place Hin/Place
:.55i{ Bolting Time (actual) 67.04 Min/Place Hln/Place
Other Cyclic Delays , 10.03 Min/Place Min/Place
--:-. Other Impositions (water, etc.) .57 _i_n/Place Min/Place
: Net Place Time v 85.57 Min/Place Min/Place
Ave. Places per Shift 2.85 Places/Shift Places/Shift::_- Ave. Place Measurement 6.27 'x 19.55'x 14.34 ' 'x ' x '
Ave. (by measurement) Raw Tons/Place 77.34 Tons Tons
Ave. Raw Tons U.S. 220.42 Tons Tons
+++.. Z Washer Reject _ 4_.90 Z " ZAve. Adjusted Clean Tons_.S. I19.2_ Tons Tons
:i Ave. (Clean) Tons/V.S. (rre.) - Ave. (Clean) TonslU.S. (Post) X IO0 = Z Productivity Lo:-:: Ave. (Clean) Tons/U. S. (Pre.)
/:: FROM STUDIES: BULK DENSITY CALCULATION:
15.18" Rock 15.18 tons 60.05 tons!:! 60.05" Coal 75.23 (0.07 --T- ) + -- (0.038 _ ) - 0.044 -------t°ns
ft 75.23 ft 3 ft375.23" Total
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..... J.J. Davis Time Study Results
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:: APPENDIX E'_:'.."t:
_: Sample Questionnaire
!-::
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1982008580-139
I:_:F 9950"601
-..-
COAL MINING ACTIVITIES QUESTIONI_AIRE
C:: Object ire
Y:.i
!_ Under contract to Jet Propulsion Laboratories, we are
,_:_ estimating the consumption of man-machine resources over a
variety of underground mining activity categories. Most of the t
_ii_I information is being obtained through statistical processing of I'F-:
our COAL Data Files. However, certain man-machine functionsb--°
F-:zare not available and must be obtained from estimates of ex-
perienced mining personnel.
t:::
The objective of this questionnaire is to identify
iii) activities performed during a shift for selected man-machine -..
functions. The percentage or fraction of the shift allocatedL:i
i__i)( tO these activities must be estimated for the following:
!..i-:_ o Section Foreman
::. o Section Mechanic-3:-=.
:.... o gratticeman
'_: O Utility Man
o Rock Dusting Machine:..:"
".V"
":: Each subject is addressed separately and contains its
'_!{. own directions. A short background statem,_.ntaccompanies each;'V
section explaining the type of information needed for that par-!:".7
'.-_! ticular person or machine.
[ii For this questionnair%, a "shift" is defined as allL"::
shift time except mant_ips and lunch. It is not necessary, how-
!:'.':
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]982008580-]40
_ 79950"601
ever,, to make estimates in minutes and then divide by shift time
to _et the correct percentage The percentage or fraction es-, •
timates w_Yl be normalized to the correct base at a later date.
iEstimates should be based upon an average shift during a typical
work week.
,1
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1982008580-141
[ 9950-601
Section Foreman
The Section Foreman has many responsibilities. He must
i: get the section activities started as soon as possible upon ar-
riving, occasionally check the miner and the bolter throughout
:: the shift, and must make sure that the section is left in safe
:: condition for the next crew. _e may also have non-routine tasks
which are only performed once or twice per week.
The section foreman's Job responsibilities seem to change
at cel-tain points in the shift, and this question_.aire has been
designed with the shift divided at five points in time:
:: (I) Mantri p Arrives - begins the available shifttIme
(2) Beuin Normal Mining Operations - initial sec-tion preparation complete; start mining coal
(3) Lunch - assumed to be the shift midpoint (e.g.,12 noon on an 8-4 shift)
(4) Finish Normal P;ining Operations - last cutmined; begin rockdusting, turn off power, etc.
(5) Mantrip Leaves - end_ a,,ailable shift time.
The purpose of the questionnaire is to define the ac-
tivities a foreman would normally perform during the time avail-
able between these five points. The questionnaire starts on the
next page.
i
1982008580-142
1 9950-601 m!_"".i
Activities Between Points (!,) and, (2) -- Mantrip Arrives - Be_inl
i ." 09erati°ns
:,.. I. What routine (daily) activities are performed during this_._ time block? Please estimate the percentage/fraction of• . the block taken up by each activity. (Suggestion- list
all activities first, then go back and assign percentages/: fractions to each activity.)
Percentage/Fract ionActivity ..... of Tim,e Block
T0tai 1.0 !
2. If some non-routine tasks are performed during this timeblock, please indicate the day(s) and the percentage/fraction of the total time block taken up by the activity.
Check Appropriate Day Percentage/FractionActivity M T W T F of Time Block
|
t
1982008580-143
F'::"
if'
I
L!:.:
Activities Between Points (3) and (4) -- Lunch - Finish O_erations
NOTE: If you believe that this time block is identicaltO the previous time block, indicate by writing
_" "SAME" across page.
r_< I. What routine activities are performe4 during this time_)i_ block? Please indicate the percentage/fraction for each' activity. '
_:._"????"
_,_ Percentage/Fraction_>>_ ACtivity of Time Block
:"..
..:.4...:,
::::"
:-:'.-'., ITotal 1.0
2. If some non-routine tasks are performed during this time-...-..= block, please indicate which day(s) and the appropriate-: percentage/fraction. !_
Check Appropriate Day Percentage/FractionActivity M T W T F of Time Block
:.:..--..
r
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]982008580-]45
9950-601 ,
_°
.:_ Activities Between Points 141 and (S) -- Finish Operations-:...... Mantr i'p Leaves
:':: i. _-at routine activities are performed during this time
!:_)i bloCk?activltyPlease, i-dicate the percentage/fractlon for each i!.ii.i:t.:::
J,,
r::" Percentage/Fract ion [[:} Acti.vity of Time Block
2:"
_..::..::-..-
.-.2.
, °
•"" Total l.0
:-- 2. If some non-routlne tasks are performed during this time
i::) block, please indicate which day(s) and the appropriatepe rcent age/fr act ion.
.5 Check Appropriate Day Percentage/Fraction
'_ Activity M T W T F of,.,Time Block
!":i
,-'..
: ,:;. ,l , .... i
(
i [:'i
_ ,, ,,, l --
1982008580-146
L
I 9950-601 •..'.'-..,
Section Mechanic
;...:
!_}}4 The section mechanic's main responsibility is to main-
rain section equipment. It is first desired to determine how
:_:• much time per shift is actually spent repairing or maintaining a
[:--: piece of equipment. The second objective is to divide his repair_':D.
time among equipment types. Finally, the mechanic's non-repair
::: time is to be divided into miscellaneous activities.
_ The questionnaire starts below.ii[:
{!_ I. In your judgement, what percentage/fraction of the shift__ is actually Spent repairing or maintaining section equip_
ment?
2. Of this actual repair and maintenance time (including pre-_:_ ventive maintenance), what percentage/fraction is spent on_ each machine? (Note: total must equal 1.0.)
Machine Percentage/Fraction=
:_:: Continuous Miner
.:._ Shuttle Cars
Roof Bolter
Section Feeder/Breaker
Other (specify)
_.-:
:.,:.
i:!-.-:
' ' T6tal l. 0
! ,
ti22.:[...:.-.,
1982008580-147
o._.
.... 3. How does the mechanic spend the remaining portion of theshift? (Note: "idle" is an acceptable answer.)
_::: Pe rcentage/Fract ion'-V."
Activity of Time Block
,_.....
:a.::
17 Total 1.0
C";
f
1982008580-148
I- Bratticeman and Utility Man
fill( It is realized that most mining sections do not have
both a bratticeman and a utility man on the face crew simultan-
t::reously, and the job functions are therefore combined. For our
lii needs, however, a distinction between the two jobs must be made.
Bratticeman_...
liliBratticeman is a UMWA job title. This person's main re-
Iii_ sponsibility is maintaining proper face ventilation by mani-L_. pulating line curtains, brattices, tubing, etc. It is doubt-
ful, however, that these responsibilities occupy the entire-- shift. The objective is to determine how the bratticeman spends[::_ his non-ventilation time. The questionnaire starts below.
_i_ I. What percentage/fraction of the shift does the brattice-i__i" man spend performing non-ventilation-related activities?
L:
[: 2. HOW is this non-ve,,tilation-related time spent? Do notcount lunch breaks and mantrip travel time.
--- Percentage/Fraction
:.i-.. Activity of Time Block
"' Total 1.0
"1982008580-]49
9950-601
i!i Utility Man
The Utility Man usually does not have a single job re-
_i sponsibility. He works wherever he is needed on the section.He may be a brattlceman's shadow, a mechanic's helper, a scoop
I_ a supply man, or even a coal shoveler at the belt feeder.driver,
The questionnaire begins below.
t':'-
_.: i. Assuming that a utility man was present on the section,i:::- how would his shift time (excluding lunch and mantrlps).... be spent? It is not necessary to break down the shift
into fine percentages/fractions: estimates to the near-:'.:_ est i0 percent are more than adequate._:_::
...--.
-- Percentage/Fraction
_::: Activity of Time Block.--.:
•::-:
;;L.
:.._ Total 1.0
°•.
..:-5;.V
L.':
•. ::.
i:L.
i:i-
1982008580-150
I
' 9950-60 !
Additional Information
F'-.
I!i_':'-'_ I. Annual mine production raw toDd/year.
_::_ 2. Estimated total number of people (salaried and hourly) on
f.'_. payroll, divided into the following categories:
Surface Operations
lii Section Production
Iiii Other Underg round
3. How is the "Other Underground" workforce split up?r.:-..
[---_: I Percentage of "Other
Job Function Undez_round" Work force
-_:.: Main Haulagebs
L.:._ Supply Sectlons
r--: Man Systems (Safety Inspe_'tors,Fire Bosses, etc.)
L..'
:--: Section Equipment MaintenanceL.:
Ventilation (other than section)i':
!.: Roof Support (other than section)
:-: Electrical Maintenance and In-
ii" stallationi_.
Supervisory
Other (please specify):
i.
2.
3.4.
..... TOTAL ' I 1.0' ', n , •
Note, Only rough estAzmates are needed-- it is not neceesary
to provide exact figures.
!
!t
|---e.,.
I. ......... _ -- mn,
1982008580-151
'I:_: 9950-60!
Comments (optional):"i_:222.
: .-:
[--
:---
!.
I
[.
, - #
f
[
.
F__
1982008580-152