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Load and Haul Fleet Selection Based on Fixed Plant Production

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Presentation on theme: "Load and Haul Fleet Selection Based on Fixed Plant Production"— Presentation transcript:

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 that You 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 New South Wales
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 ? The End

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

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

14 Load & Haul Work Hours per Day

15 Load & Haul Work Hours per Day
Load and Haul Scheduled Hours / Day 10 hours less Non Operational Time Mobilisation Toolbox Talk - Inspect - Transit minutes Transit - Refuel - Shut Down 20 minutes Breaks including Transit time AM / PM Breaks minutes Lunch minutes Subtotal of Non Operational Time hours less Non Primary Load and Haul Stock movement hours Overburden hours Subtotal Non-Primary Load and Haul hours Work Hours per Day hours

16 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. Efficiency Operation Working Hour Factor Day 50 minute hour Night 45 minute hour 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 ?

17 Analysis of Face Loader Activity

18 Concepts Time Available Material Density Fleet Match
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

19 Density of Materials Material Bank Loose Load kg/m 3 kg/m 3 Factor
Gravel - pit run Earth-dry Earth- wet Clay – natural bed Topsoil Shale Granite -broken Limestone Full Table in PHB 42 P27-4

20 Concepts Time Available Material Density Fleet Match
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

21 Machine Production CYCLE TIME Operator Skill LOAD Fixed Time
RETURN Variable Time Delays HAUL Variable Time DUMP Fixed Time

22 Loading Tool / Hauler Pass Match
Target Truck Load Time 2 minutes Target Exchange Time 0.7 minutes Target Pass Match Loader / Hauler = 3-5 Excavator / Hauler = 4-6

23 Concepts Time Available Material Density Fleet Match
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

24 Bucket Fill Factor (BFF) BFF as % of Heaped Capacity
Material Moist Loam Sand and Gravel Mix Rock - Well Blasted Rock - Poorly Blasted 12 –20mm Aggregate BFF as % of Heaped Capacity A % B % C % % This overhead gives a rough idea of the kinds of fill factors you can expect in various types of materials. This can also be found in the Performance Handbook. When doing calculations, we typically use the midpoint of the range. A B C 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

25 Quarry Contacts Queensland and Northern Territory New South Wales
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

26 Any Questions ? The End

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