1. Trackless Mobile Mining Machinery Operation
“Safety Risk Model
Trackless Mobile Mining Machinery Operation
for
South African
Open Pit/Cast Operations
An Industry wide perspective

2. Open Cast/Pit MOSH

3. Purpose
The model is a corner stone for the MOSH initiative’s process to identify Leading Practices with the potential to make the biggest contribution to industry wide Safety performance for trackless mobile mining machinery operation

4. Outcomes of the exposure
Level One: Overall Model
Equipment
Short term outcomes
Injury
Disability
Death
Production loss
Sec 54
Sec52
Body and organ vibration
Hand and feet injuries
All ranges of body injuries
Nature of Exposure
Operator
Nature of the Hazard
Exposures
Outcomes of the exposure
Information
Exposed persons
Environment
Machine Operators
Maintenance Technicians
Workers/Pedestrians
Long term outcomes
Injury
Disability
Death
Lower ROI
Increased
regulation
Compensation
Equipment operation

5. Level two: Sources of Equipment Hazards
OEM
Inadequate definition of use/poor understanding of use.
Inadequate field testing of equipment/components
Inadequate risk analysis for specific requirements
OEM design process inadequate
Inadequate user field feedback
systems
Lack of safety engineering competence
Inadequate operability and maintainability analysis
Poor/no Human factors engineering
Inadequate design specifications
Company
Lack of user acceptance testing of
new equipment designs
Inadequate user requirements specifications
Equipment
Fatigue failure of safety related
components
Nip point on machines
Inadequate
Safety Systems Design
Difficult/poor access for Persons working on Vehicle
Machine fires
Poor Ergonomics/HF of Machines
Inadequate provision
For
Visibility
Difficult/poor access for operators
Poor Maintainability/maintenance access
Poor reliability of
Safety Systems
Poor provision of
Safety Systems by OEMs
Level two: Sources of Equipment Hazards
Level three:
Causes of Equipment Hazards
Equipment failure

6. Level two: Sources of Operator Hazards
Poor fitness
For work
Operator complacency
Inadequate training
Inadequate competency assessment –no emergency simulation
Dangerous Operating of machine
Operator Fatigue
Poor Literacy/ risk comprehension
Poor Safety Culture
Pre use inspection
Man / Machine
misfit
Old drivers
No test of risk
Comprehension
Inadequate driver training
and experience
Production pressure
Poor risk comprehension
Over confidence/familiarity
Lack of emergency experience
Poor eye sight
Physically unfit
Medication impact
Poor Health
High risk tolerance
Cultural
National
Social
Lack of understanding
cause & effect
Overly elaborate
check list
Checklist/Literacy level mismatch
Checklist not risk based
Complacency
No review of checklists
Poor selection criteria
(Ergonomic review)
Historic selection
New model machines
old operators
Not using / wrong use of PPE
Familiarity
Poor safety culture
Inappropriate PPE
Ineffective PPE
Double standards
Poor understanding
of importance of training
Inexperience with training design
Cost of effective training
programmes
Difficulty to measure
training effectiveness
Bridging safety devices
Nuisance alarms
Poor reliability
Sabotage
perceived production
impact
of importance
Inexperience with design
of competence assessment
Challenges to measure
Risk to simulate
Cost to simulate
Level three:
Causes of Operator Hazards
Machine Vibration
Lack of sleep
Shift patters
Distance from work
Repetitive work
Poor discipline wrt medical
Substance abuse
Social conditions
Poor physical condition
Poor mental condition

7. Level two: Sources of Equipment Operation Hazards
Inadequate understanding of
fully functioning equipment
and safety relationship
Level three:
Causes of Equipment
Operation Hazards
Inadequate understanding
of leading practices in traffic management
Traffic management not fundamental
mine design focus
Inadequate traffic management
Poor equipment health standards
Poor safety culture
Inadequate understanding of full functioning equipment and safety relationship
Capital cost constraints
Non systemic approach
to mine design changes
Safety impact assessments not
always done
Temporary vs Permanent
Production only considerations
Inadequate mine design/layout/
mine capacity changes
Lack of maintenance infrastructure
Inadequate awareness of new and leading practices
Poor continuous improvement process
Capital constraints
Reviews after incidents inadequate
Equipment operation
Safety controls too low on hierarchy of controls
Operating procedures
evolved over many years
No physical verification of
operating procedures
Office based procedure review
Composition of review teams
Sub-standard and
unpractical operating procedures
Mismatch of operating procedures and mine design.
Poor management of mine design changes
New operating procedures not considered and/or not practically verified before issuing
Copy and paste of procedures
Poor roads-surface and gradient maintenance
Roads-surface and gradient standards are inadequate
Poor safety culture from management
Road surface maintenance not considered as critical for safety
Insufficient Recovery Standards and equipment
Standards not established for specific environmental conditions
Standards not established for specific equipment characteristics

8. Level two: Sources of Information Hazards
Level three:
Causes of Information Hazards
Inadequate/no operator
communication
systems
Poor spotter
signals .
Information or the lack thereof is not generally viewed as a source of hazards
Risk of no/poor information not formally assessed
Lack of/late ground stability information
Information
Failure of GPS systems
Lack off/late incident information
Late/incomplete roads-surface and gradient condition information

9. Level two: Sources of Environmental Hazards Causes of Environmental
Sudden Flooding
Level three:
Causes of Environmental
Hazards
Fall of Ground
Lightning
Dust
Environment
Rain