TCI Operations Training Program - GETA Production & Equipment Management Tool

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Name: Calvin Day Venue: TCI Operations Training Program Satui Mine Date: 16th July, 2007

Cost Per Tonne SensitivityA 5% Change in Each of these Factors Results in the Following Reductions in Cost per TonneFACTOR 0% Operator Efficiency Cycle Times Payload Maintenance and Repair Operator Wages Fuel Consumption Tyres ** Machine Capital Lubricants Mechanical Availability UtilisationApproximate range of final results based on analysis to date. Cost parameters including fuel may vary greatly by location and application. 2

REDUCTION IN COST PER TONNE 1% 2% 3% 4% 5% 6% 7%

AVERAGE 5.56% 5.00% 4.76% 1.68% 1.05% 0.85% 0.73% 0.63% 0.06% Variable Variable

Introduce stress into the GET system ( inefficient penetration via selection, operation or maintenance) you: Increase the load on the machine Make the machine work harder More power More twisting

GET is a system GET is a part of the implement system Increase the CPT The implement is part of the machine system If the implement is not positioned correctly it will drive load back into the machine & GET

Driving excessive load back into the machine will Driving excessive load back into the machine will cause it to fail at the weakest point cause it to fail at the weakest pointFatigue Fatigue Components not designed or intended to accommodate that load Components not designed or intended to accommodate that load3

Condition Monitoring = S.O.S

CPH4

CPT

Elements of Wear Contact Relative motion Abrasive Pressure5

OperatorsEfficient

(Optimal performance)

Reduce Cost per tonne

Coaching Coaching Management ManagementIncrease Productivity

Competent & CertifiedTraining Training

New

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992G Tip Tip change Tip CPH Fuel burn (70 102 l/hr) Combined CPH (11)% + 2% + 41% + 33% +44% HDA + 32% (22)% (45)%

D11N Edge System Edge system change Edge system CPH Fuel burn (109 117 l/hr) Combined CPH08/06 fuel price

+ 60% (68)% + 7% + 3% +6% (26)% +119% +148% K +44% (6)%

345BL PP tip to: Tip price Tip CPH Production Tip Spend up $39,536 $57,430

988G System change System CPH

990II HD Rock Bkt J to: Tip life Fuel burn (81 76 l/hr)

Loader System 7

System change 992G production 994 production - system A 994 production - system B

Cheaper (?)% (11)% (9)% (4)%

Months to regain loss

1.3 1.0 0.5

What is wrong with this picture?

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Loader Operator Technique Bottom of bucket should be clear of the floor and shadowed by the tipsDo not allow bottom of bucket or wear plate to contact the floorIncreases resistance Reduces penetration Reduces production Increases cost for no gain

Keep clear of floorMaterial Flow

Keep clear of floor- Optimal position to load Base edge parallel to the floor 9

Maintain bucket positioner in proper alignmentBase edge parallel to floor

GET Boneyard Analysis (cont)

WTL

Wear out on at the bottom of 994 bucket tip Results in Reduced production Over clean work area (in coal not an issue with tyre cuts) Loss of tip life

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Excellent Tips just touching the toe at entering the face No heel contact No excessive floor cleaning

Dont reward poor technique!13

Loader Operator Technique

Raise lift arms before crowding bucketMaximize production Reduces contact pressure to reduce wear Enables heel plate clearance Minimize ground contact Transfers weight to front tires to balance14

Keep heel clear of floor Only tips just touching the floor

Heel Wear The heat and mushrooming a result of the excessive contact Need to raise the lift arms before curling

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Loader Operator TechniqueEnter the pile with the bucket square to the face More contact on one side Equals more wear Stresses bucket, linkage and hinge pin

RHS RHS

LHS Adapters wear on LHSone side and weld is washed out

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Loader Operator Technique Bucket to be parallel to the face when loading Parallel to the body when dumping Loader to lead operation by spotting the hauler so loaders can penetrate the face square and dump square to the body Operator training for both loader and hauler to ensure the proper spotting technique and lift arms do not contact the body

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Loader Operator TechniqueMinimize ground contact Make the tips / edges do the work

Excessive contact Excessive clean up = Excessive GET $19

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Graders

Turn this:

Into this:

Increase truck productivity Increase speeds Reduce spillage Reduce gear changes Decrease truck costs Reduce tire cuts & wear Increase truck availability reduce component & frame wear Reduce fuel burn

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MG Operator TechniqueDo not use excessive speed Do not use excessive downward pressure Use accumulator to absorb shocks Typical applications performed under 10 kph (6 mph)

Speed + Pressure = Wear

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Grader 16 Too fast Too much bounce Poor finish Reduced cutting edge life

Could use less cast angle More coverage per pass Helps reduce speed

Good tip angle

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16H

Mushrooming24

Grading too fast Mushrooming on cutting edge occurs when edge gets too hot and softens Increases wear rate and reduces life ( operated outside design envelop ) Typically due to running machine too fast

No contact on RHS Corner loading the LHS Full contact for haul roads

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Whats wrong with this picture?

Excessive speed DamageCircle drive box gears - 1264 hrs Circle drive pinion clutch Drawbar group Tires Cracking Wear Cap mountsHigh traction tyres fitted due to wheel spin complaints and short tyre life. Sliding contact stress fatigue High load wear

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Grader 16H Blade pitch too far backLarge footprint hard to penetrate

Larger footprint harder to penetrate Higher wear Drops bolt & nut into wear zone

35 mm thick cutting edge will also reduce penetration Recommend Optimum pitch for hauls road maintenance is tip 50 mm ahead of the toe 25 mm cutting edge

Angle of wear denotes the angle of operation (blade pitch) 27

MG Operator Technique Motor GradersBlade Position

Keep top of moldboard ahead of cutting edge100 mm for 24H 50 mm for 16H downTIP

Keep edge at 90 angle to surface. Maintain constant tip angleTOE

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LHEX & HEX Operator Technique

Enter face squarely Dont swing into pile

Avoid using excessive prying force Tips and the adapters are designed to break first

Minimize bucket Minimize bucket ground contact ground contact Make the tips do the work Make the tips do the work29

LHEX & HEX Operator Technique Note difference in the position of the boom .. and bucket

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LHEX Excessive top wear Should wear from bottom up Bkt being curled away from face Check if bench height is too low Start dig with stick further out & keep throat of bucket open Keep tips in contact & minimise bucket contact Increases load on machine Reduces production

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Dual Radius Design reduces heel drag while maintaining capacity. Benefits of this design are: Increased loadability Reduced wear Reduced maintenance costs While digging, avoid any heel drag & contact Benefits are:Increased loadability Reduced wear Reduced maintenance costs

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LHEX 5230 Cleaning the face Corner loading Very high tip adapter load

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Wheel Type Dozer Operator Technique

Different to Dozers Blade Angle: Designed to roll, not carry material Back of blade to be VERTICAL to ground

Sole plate: Designed to restrict penetration and prevent tire recoil Not designed to carry the blade

Sole plate to be horizontal

GET to sit flat on the floor For road & pit clean upBlade in float Pitch in neutral

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Wheel Type Dozer Operator Technique

Things to watch for: Keep loads small and material should roll Avoid excessive down pressure Push the load keeping machine straight as possible Minimize heel-plate contact Maintain full blade contact with floor Keep heel plate parallel with floor and back of blade vertical

Need mining application shot

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Inefficient blade technique

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Dont reward poor operator technique

WTD Dozer 844 Excessive speed Exceeded design envelope Mushrooming 400o C

844 End Bit

Excessive speed see mushrooming39

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Ripper Ripper Shank Angles Operator Technique

Initial Penetration

Production Penetration

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Proper Ripping Pass

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D8

How a worn out tip should look

26% wear life remaining44

D8

Need to see more chrome!!!

Engine RPM just above idle Operating ripper control only

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Excessive Speed

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Ripping rework Island of coarse materials No previous field preparation Low availability Poor ergonomic conditions

Increased productivity Increased availability Reduced dozer cost Reduced GET cost Reduced machine fatigue

Before

After

Ripping Before Training4,50 4,00 3,50 4,50 4,00 3,50

Rippering After Training

m/s2

m/s2

3,00 2,50 2,00 1,50 1,00 0,50 42:00 42:10 42:20 42:30 42:40 42:50 43:10 43:20 43:30 43:40 43:50 44:00 44:10 44:20 44:30 44:40 44:50 45:10 45:20 45:30 45:40 45:50 41:50 43:00 45:00 46:00 0,00 46:10

x y z

3,00 2,50 2,00 1,50 1,00 0,50 14:44:30 14:44:50 14:45:10 14:45:20 14:45:40 14:45:50 14:47:30 14:47:40 14:48:00 14:44:40 14:45:30 14:44:00 14:44:10 14:44:20 14:45:00 14:46:00 14:46:10 14:46:20 14:46:30 14:46:50 14:47:00 14:47:10 14:47:20 14:47:50 14:48:10 14:43:50 0,00 14:46:40 14:48:20

x y z

tempo (s)

tempo (s)

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Dozer Operator Technique

Doze in 1st gear Avoid excessive speed Use slow steady prying force Dont corner load Blade Angle - Carry, dont roll Big loads slow49

Optimal blade technique

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Dozer Operator Technique Center edges worn before End BitsBlade cutting during carry mode Blade not raised during carry Wear material not utilized Unnecessary wear on moldboard Unbalanced system wear, increased downtime51

Incorrect shape dozing Using Steering Clutch during operation Low productivity Intense wear of the end bits Damage of the blade

Higher productivity Two or more bulldozers on bench Safer Uniform GET wear Reduced GET usage

Before

After

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Operator Site AssessmentImplements

Machine operation & implement usage to maximize productivityInsert and crop your own photo here

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Calvin Day February 2007

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Elements to Optimize Equipment Operation In Pit supervision Production studies Operator Site Assessment Tool GET condition monitoring

Operations Inspections GET condition monitoring Operator Site Assessment Tool

Maintenance

Training

Production studies Training material Operator Site Assessment Tool GET condition monitoring

Optimal / Max. ProductionMaintenance MaintenanceTires / Tracks Tires / Tracks

Production Production

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Fuel Fuel

Operator Techniques & Your GET PEBJ0001Pit Management ToolPEBJ0001

Operating Techniques and Your GET CD PEXT9050

Use in conjunction with:PEXT9050 AEXQ003055

GET Operating Tips

Operator Techniques and your GET Reference guide to Mining Machine Application

Video

PEVP4009

Question #1 There are two things which tell when a wheel loader bucket is in the most efficient position to enter the face. What are they? Base edge parallel to the floor Tip pocket wears evenly top and bottom

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Question #2 Motor graders are operated at what speed for typical applications? Under 10 kph

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Bonus Question What are the four Ps to GET success ? Protection Penetration Performance Passion

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Terima kasih

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