ACARP Roadway Development Operator Workshop No 7

1. ACARPRoadway Development Operator Workshop No 7 A Systems Approach to Roadway Development Mick Kelly, BMA Coal

2. Safety, Safety, Safety

3. A Systems Approach to Roadway Development • Components of Roadway Development • Outline of “Systems Approach” • Hierarchical Components • Focus on Process Improvement • Importance of Information Flow

4. Process Pumping Mining Cr ew Miner Standards Conveyor Commu- nication Shuttle car Roadway Maintenance Roof Support Panel Set-up Bonus Advance Hazard Ma ps Power Pro cess Improvement KPI’s Roster Maintenance Systems Ventilation Gas Control Safety Stone- dusting Culture Training

5. Systems Approach ? Firstly, a systems approach incorporates people issues and technology into processes – People are Pivotal

6. Systems Approach Secondly, a systems approach must understand the complexity of systems structure and the dynamics of the interactions between processes.

7. Systems Approach Thirdly, a systems approach recognises natural variability is a normal part of any process.

8. Systems Approach • Lastly, a systems approach recognises that the collection and use of information is a key factor. • “Information is Data that Informs”

9. Key components and interactions of the existing system • Mining Systems (cutting, bolting, transporting) • Organisational Factors (manning allocation and organisation, measurement systems and motivational factors) • Machinery Supply and Support • Strata Support and Gas Control • Systems Support (panel layouts, extensions, gas and water drainage, ventilation, floor control) • Maintenance Practice • The Human Element (workforce, management, culture, industrial environment) • Safety Systems

10. Roadway Development Models The first model is a simple form of process mapping (or a simple project management Gantt chart)

11. The key questions to be answered are: What is the process map at each level of the hierarchy? What is the interaction between hierarchies? Who is responsible for the overall process at each hierarchical level? For each of these levels what is measured and what is the focus? Hierarchical Model

12. Mine Improvement Areas? • Roster Design – Is the roster currently maximising face, maintenance, set-up times? • Formal Introduction of Process Improvement? • Maintenance management system tailored to roadway development requirements? • Focus on data management for process improvement, not historical data collection for upwards summaries. • Bottom Line - STRONG FOCUS REQUIRED ON ENABLING TEAM TO IMPROVE PROCESS KNOWLEDGE AND INCREASE THEIR ABILITY TO INFLUENCE

13. Panel Improvement Areas ? • Separation of Panel with Mains – achieving that “push button start” • Use of project management approach in mains driveage • Panel Plan, • Standard Area Methods • Integration of activities • Supply systems & wastage • Hazard Plan, short interval control, feedback loops • Communication Plan • Methods • Reinforcement of Best Practice • Formal feedback loops • Hazard treatment, response time • Travel Time into face • Total cost of driveage • Design & Deliver Technology pack to allow cycle optimisation

14. Standard Area Methods Aims: • standardise the method of development across the shifts • establish “best” practice • improve people’s knowledge of that practice • formalise a process that will allow crews to initiate improvement.

15. Pillar Cycle Improvement Areas? • Focus of Continuous Improvement into pillar cycle • Optimisation of panel extension • decoupling of non-critical tasks • teamwork interaction and training • “example” belt move • review after each pillar • Standards for longwall operation • Maintenance shift <> hot start both ways

16. Face Cycle Improvement Areas? • THROW OUT SHIFT TARGETS • Understand constraints on uptime rates – empower team to remove • Understand constraints on utilisation time – empower team to remove • Reinforce cutting cycle optimisation • Reinforce panel standards • Reinforce alternative work options • Ensure effectiveness of maintenance delivery

17. Systems Approach Emphasis on: • Process improvement • Use of Information

18. Natural Variation

19. Decreasing Variation

20. Reducing Variation of Sub-processes

21. Continuous Improvement

22. Step Change

23. Information the Key Remember information, not data is the key for success: • Information should be analysed not averaged • Setting effective KPIs is essential • Effective analyses for process improvement • Information should be 50% downward • Feed back loops are a necessity for exception reporting • Use reviews to improve process knowledge

24. Site Commitment The commitment from the mine will need to include: • A desire to improve performance. • Acceptance that this will involve a change process. • Process must involve faceworker, middle management as well as senior management support. • Process may involve a major change in the way information is collected and used. Key to the Success • Site commitment to Roadway Development improvement to ensure it is fully integrated with all site activities

25. Some Takeaways • Take the blinkers off with safety • Holistic Approach – don’t just focus on face equipment • Define the process & give it an owner • Use Process Improvement to attack waste • Information to the process teams to drive improved knowledge and empowerment • Site commitment is essential A systems approach incorporates people issues and technology into processes – People are Pivotal