Load and Haul Fleet Selection Based on Fixed Plant Production

1. Load and Haul Fleet Selection Based on Fixed Plant Production

2. Load and Haul Fleet Selection Based on Fixed Plant Production

3. Ways to Estimate Productivity !!

4. The typical view is machine centred …

5. What are we going to do ? • Review an approach which uses Crusher Output to drive fleet selection. • Use a simple spreadsheet to manage this process e.g. no bunching or cycle mismatch included. • Tie in the relevant concepts of earth and rock moving into this process. • Seek to reinforces the outlook thatYou can’t Manage what you don’t Measure !

6. Key Questions Addressed What are the Production Targets and Rates for Fixed Plant? How much Time is Available? What Primary Load & Haul Production is required? How much of an Hour does the Loading Tool spend Loading? What is the Load Area Production Rate ? What are the Cycle Times for Haulers and Loading Tool? What is the Match of Loading Tool and Haulers ? What is the Key Characteristic of the Material? What does our Reality look like?

7. Bunching and Cycle Mismatch

8. Quarry Contacts • Queensland and Northern Territory • Paul Soden Hastings Deering, Brisbane • New South Wales • Andrew Black WesTrac, Sydney • Victoria • Ian Collins William Adams, Melbourne • Tasmania • Stuart Mc Donald William Adams, Launceston • South Australia • Mark Taylor Cavpower Adelaide • Western Australia • Steve Sakich WesTrac Perth

9. Any Questions ? TheEnd

10. Concepts • Time Available • Work Days per year • Work Hours per Day • Job Efficiency – Work Minutes per Work Hour • Load Area Activities • Material Density • Load Factor and Fragmentation • Fleet Match • Cycle Times • Bucket to Body Sizing – Effective Pass Ratios • Bucket Fill Factor

11. Concepts • Time Available • Work Days per year • Work Hours per Day • Job Efficiency – Work Minutes per Work Hour • Load Area Activities • Material Density • Load Factor and Fragmentation • Fleet Match • Cycle Times • Bucket to Body Sizing – Effective Pass Ratios • Bucket Fill Factor

12. Availability & Utilization An Example Job Efficiency Factors Machine Availability Loss Off Time Loss Utilization Loss Mismatch Unscheduled Downtime Holidays Ready, but unmanned (90% On-Shift Availability) Bunching Weather Shift Change Operator Efficiency (4.1% Off Time) Lunch & Meetings (85% Job Efficiency) Scheduled Downtime &PM's (87.5% Utilization) 735 1050 360 PRODUCTIVE TIME HRS HRS HRS 6615 HRS Machine Operating Hours 12.5% 4.1 % (6615 HRS) of 10 % of 8400 Machine Scheduled Hours of 8760 (7350 HRS) 7350 Mine Scheduled Hours (8400 HRS) Total Annual Hours (8760 HRS) Work Hours Available per Year

13. Full Days 220 days Partial Days 48 days Partial Day Factor 0.50 Work Days per Year

14. Load & Haul Work Hours per Day Load and Haul Scheduled Hours / Day10 hours less Non Operational Time Mobilisation Toolbox Talk - Inspect - Transit 20 minutes Transit - Refuel - Shut Down 20 minutes Breaks including Transit time AM / PM Breaks 20 minutes Lunch 45 minutes Subtotal of Non Operational Time 1.75 hours less Non Primary Load and Haul Stock movement 0.75 hours Overburden 0 hours Subtotal Non-Primary Load and Haul 0.75 hours Work Hours per Day7.5 hours

15. Job Efficiency /Work Minutes per Work Hour Job Efficiency is one of the most complex elements of estimating production since it is influenced by factors such as operator skill, minor repairs and adjustments, personal delays and delays caused by job layout. An approximation of efficiency, if no job data is available, is given below. EfficiencyOperation Working Hour Factor Day 50 minute hour 0.83 Night 45 minute hour 0.75 These factors do not account for delays due to weather or machine downtime for maintenance and repairs.You must account for such factors based on experience and local conditions. What about time lost for watering the load area ?

16. Analysis of Face Loader Activity

17. Concepts • Time Available • Work Days per year • Work Hours per Day • Job Efficiency – Work Minutes per Work Hour • Load Area Activities • Material Density • Load Factor and Fragmentation • Fleet Match • Cycle Times • Bucket to Body Sizing – Effective Pass Ratios • Bucket Fill Factor

18. Density of Materials Material BankLoose Load kg/m 3 kg/m 3 Factor Gravel - pit run 2179 1930 .89 Earth-dry 1900 1510 .80 Earth- wet 2020 1600 .79 Clay – natural bed 2020 1660 .82 Topsoil 1370 950 .70 Shale 1660 1250 .75 Granite -broken 2730 1660 .61 Limestone 2610 1540 .59 Full Table in PHB 42 P27-4

19. Concepts • Time Available • Work Days per year • Work Hours per Day • Job Efficiency – Work Minutes per Work Hour • Load Area Activities • Material Density • Load Factor and Fragmentation • Fleet Match • Cycle Times • Bucket to Body Sizing – Effective Pass Ratios • Bucket Fill Factor

20. Machine Production CYCLE TIME Operator Skill LOADFixed Time RETURNVariable Time Delays HAULVariable Time DUMPFixed Time

21. Loading Tool / Hauler Pass Match Target Truck Load Time2 minutesTarget Exchange Time0.7 minutesTarget Pass MatchLoader / Hauler = 3-5Excavator / Hauler = 4-6

22. Concepts • Time Available • Work Days per year • Work Hours per Day • Job Efficiency – Work Minutes per Work Hour • Load Area Activities • Material Density • Load Factor and Fragmentation • Fleet Match • Cycle Times • Bucket to Body Sizing – Effective Pass Ratios • Bucket Fill Factor

23. A B C Bucket Fill Factor (BFF) Material Moist LoamSand and Gravel Mix Rock - Well Blasted Rock - Poorly Blasted 12 –20mm Aggregate BFF as % of Heaped Capacity A - 100-120 % B - 95-110 % C - 80 - 95 % 50 - 75 % 85 - 90 BFF for Wheel Loader buckets tend to be 5 – 10 % higher than Excavator buckets due to different angles of repose for SAE rating. PHB 42 Pages 4-156, 9-161

24. Quarry Contacts • Queensland and Northern Territory • Paul Soden Hastings Deering, Brisbane • New South Wales • Andrew Black WesTrac, Sydney • Victoria • Ian Collins William Adams, Melbourne • Tasmania • Stuart Mc Donald William Adams, Launceston • South Australia • Mark Taylor Cavpower Adelaide • Western Australia • Steve Sakich WesTrac Perth

25. Any Questions ? TheEnd