Our client operates a number of mines, due to the size of the mine & complexity of equipment shift change is time consuming, this nonproducing shift change duration reduces the ore delivery to ore preparation, affecting the flow of production.
A team from the mine were tasked with improving shift change, they came together and created a fishbone diagram, cause & effect diagram, of all the issues, pain points, impacting shift change.
This exercise demonstrated opportunities with method of shift change, condition of roads, coordination of personal vehicles, busses & equipment, operators lack of understanding of their responsibilities re shift change & opportunity to improve communication & coordination.
Daily Kick Off meeting done after driver are in trucks, over the radio instead of time consuming meetings.
Check in and ride out procedure for drivers tightened up to reduce misunderstandings (process “5S” orderliness, efficiency and safety enhancement of arrival/departure area (parking lot) with designated locations for specific ride out vehicles
The changes delivered an annualised bitumen increase of 9,000 tonnes/day generating a revenue increase of $110m.
OPEX was reduced by $4.7m, made up from $3m reduction in truck rental & $1.7m reduction in energy consumption.
CO2 reduced due to reduction in energy use 28.1kt CO2 per/year
Morale of staff increased through engagement in the improvement activity & making their working life safer.