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Progress on implementation of drill jigs at Impala
Investor visit28 October 2005
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Factors impacting team productivity
• Older shafts with high team efficiencies being replaced by new deep level shafts
• Distance (horizontal) from barrel affecting face time and thus mining cycles (affects blast frequency)
• Traveling time down decline affecting face time (blast frequency affected)
• White area mining (20% of total centares)
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3
Technology intervention
• Drill-jigs (DDT) technology on the Merensky horizon
• Including in-stope bolting as a support system
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Potential DDT benefits
• Primary benefits• Safety
• Remove rockdrill operators from danger area• Permanent support close to face• Reduction in number of FOGs
• Secondary benefits• Reduced physical effort• Improved productivity
• Assuming a blast frequency of 19 blasts/month• Potentially 1.2m advance per blast• Realistically 1.0m advance per blast
• Cost or ounce benefit• Reduction in labour complement (natural attrition)
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5
Drill jigs - Stoping
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Drill jigs - Stoping
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7
Drill jigs - Stoping
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Drill jigs - Gulley
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Team learning curve (built into 5-year plan)
530m²/team
450m²/team
Training+ 1 month bolt lead
± 12 months (Benefits)
± 3 months(breakeven)
± 5 months (Improvement)
± 8 months (Payback)
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Progress over 7 months – learning curve
360
380
400
420
440
460
480
CA
's/T
eam
CA's / Team 428 423 422 402 450 467 422
Base CA's 425 425 425 425 425 425 425
Ave CA's 428 426 424 419 425 432 431
1st Month 2nd Month 3rd Month 4th Month 5th Month 6th Month 7th Month
YTD = 437Base = 425
Improvement = 3%
Last three months ave. = 446 CA’s
= 5% impr.
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11
Roof-bolting: Progress of roll-out (as at 22 October 2005)
20 Teams behind schedule
80
100
120
140
160
180
200
Team
s
184 TeamsOct ‘05
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Drill jig: Progress of roll-out (as at 22 October 2005)
40
50
60
70
80
90
100
110
120
130
Week
Team
s
Actual 48 53 57 58 61 63 64 66 68 69 70 72 75 76 77 77 81
Plan 47 50 55 57 61 64 69 70 75 77 82 85 89 91 95 98 101 104 107109 111 113 115 117 119 121 123
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
20 Teams behind schedule
81 Teams on DDT
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13
Falls of ground
Double Roll-Out
Falls of ground larger than 4m2 - Impala Platinum
48 50 51
812
1611
912
85
11 11
47
1013 11
9 7 813 13 12
16
911
9
18
6 63 5 6
9
15 4
116 4 4 3
0
10
20
30
40
50
60
Month
No.
of F
OG
's
GCDs200mm RS Straps Strocams
In Stope Bolting
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New technology - flat-end development
• Improved safety, operator removed from face area
• Increased face advance per blast
• Consistent and parallel drilling
• Mini-bolter also designed to utilise same boom and act as a carrier to transport the equipment in and out of the ends.
• Less physical effort required by operators
• Less skill required to drill holes
• First jig currently undergoing trials at 10 shaft
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Factors affecting drill jig implementation
• Slow uptake by above average performing teams.
• Prioritisation of roofbolt roll-out
• Training period takes longer than anticipated.
• Teams require consistent monitoring and coaching after training.
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Risk associated with DDT implementation
• Lack of total union buy-in
• issue of job losses
• System not properly tested, with regard to:
• Work cycles (especially bolting)
• Machine reliability (breakdowns)
• Supplier back-up
• Machine maintenance
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The way forward
• Drive R&D into and trials on bolters of less than 1m for the UG2 (±85cm)
• Drive R&D into and trials on development technology to ensure availability of developed reserves
• Revisit efficiency improvements in FY2007 and beyond, however FY2006 required as a learning period.
• Continue driving implementation of best practice to maintain and improve current efficiencies, especially on development.
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Targets for FY2006
Merensky drill jig teams:
455437CAs per team
4240CAs per panel man
18081No. of teams
TargetCurrent
10
19
Envisaged improvement
Ca/Panel Man - DDT Technology (Merensky)
40
42
4647
30
32
34
36
38
40
42
44
46
48
Current RealisticEfficiency
Cen
tare
s / P
anel
Man
0,85madv/blast
19/23blasts
450 Ca's
1,0madv/blast
19/23blasts
472 Ca's
1,0madv/blast
19/23blasts
511 Ca's
1,0madv/blast
19/23blasts
530 Ca's
5%
10%
2%
Progress on implementation of drill jigs at Impala
Investor visit28 October 2005