BMC Fleet Management System and IROC Transition

Benchmarking Truck and Digger Time Usage and Performance

BHP Coal Intern Final Presentation
Jack Kent
Undergraduate Mining Engineer
05/02/2018
My Background

• Fifth Year Mining Engineering Student at

The University of Adelaide
• Part time study in 2018 to finish a Mine to Mill
Optimisation at a SA Open Pit Copper
Operation as part of my Thesis

• Underground Dump truck operator in

Meekatharra, WA at the Andy Well Gold
Project

• Studied in the USA in 2017

• Colorado School of Mines & several mining
operations in Nevada, Arizona and Colorado
Introduction & Definitions
• Current State - Load Unit Hang Time:
• Hang Time start – End of loading of previous truck (triggered by kick out switch or touch screen)

• Hang Time End – Start of loading current truck or operator initiated activity (e.g. start of delay)

Hang Time Loading (first bucket) Kick out (end of load) Delay (or Start of Hang)
Hang Time Load Time Delay (or Start of Hang)
Load Unit Cycle Time (Production Time) Delay

• Current State – Truck Cycle:

Queueing Loading (first bucket or Kick out (Loader kick

Arrives at Wait for Travel Loaded/Dump/
(not for Spotting Truck Operator selects out or truck moved
Loader Load Travel Empty
first truck) loading) away by 25 m)

Truck Cycle Time

BMC Time and Motion Study

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Introduction & Definitions
• Proposed Transformation of Load Unit Production Time Reporting with FMS installation
Production Time

Hang Time Load Time

Load Unit Loading (first bucket Kick out (Loader kick
Truck Truck Truck Waiting
Waiting For or Truck Operator out or truck moved away
Queueing Spotting For Load selects loading) by 25 m)
Truck To Arrive
Hang Time Hang Time Hang Time
Hang Time True
Queue Spot Remainder Load Time
Where, 𝑯𝒂𝒏𝒈 𝑻𝒊𝒎𝒆 𝑻𝒓𝒖𝒆 = 𝑻𝒐𝒕𝒂𝒍 𝑯𝒂𝒏𝒈 𝑻𝒊𝒎𝒆 − 𝑯𝒂𝒏𝒈 𝑻𝒊𝒎𝒆 𝑸𝒖𝒆𝒖𝒆 − 𝑯𝒂𝒏𝒈 𝑻𝒊𝒎𝒆 𝑺𝒑𝒐𝒕 − 𝑯𝒂𝒏𝒈 𝑻𝒊𝒎𝒆 𝑹𝒆𝒎𝒂𝒊𝒏𝒅𝒆𝒓

Essentially,
Hang Time True = Time Spent by Load Unit waiting for trucks to arrive = Reported Hang Time Value
Hang Time Queue = Time spent by truck in queue while load unit is in “Hang”
Hang Time Spot = Spot Time at Load Unit
Hang Time Remainder = Truck Wait for Load *Observed to have minimal influence on hang time at PTM and SWC, therefore excluded
from this analysis*
BMC Time and Motion Study
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Manual Time and Motion Data Collection Summary
Site Date (Shift) Load Unit Code Make/Model Excavator Class
11/01/2018 (D) EX53 Hitachi EX3600 Small Excavator
SWC
12/01/2018 (D) EX12 Hitachi EX5600-6 Large Excavator
EX36 Terex O&K RH340B Large Excavator
29/01/2018 (D)
EX153 Hitachi EX3600 Small Excavator
PTM
30/01/2018 (D) EX36 Terex O&K RH340B Large Excavator
31/01/2018 (D) EX02 CAT 6060 Large Excavator
Limitations/Assumptions

• Limited data collection may misrepresent annual performance due to one off issues and small sample size.

• Assuming Daunia and BMC operations will have similar performance post BMC FMS installation

• Only dayshift data collected

• Data collection from digger only

• Unable to collect data for an entire shift meaning delay data may not be an accurate representation of entire shift

• EX36 and EX153 (PTM) circuits sharing common dump location – may result in inflated dump queue time

• No coal mining data collected

BMC Time and Motion Study
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 Major Findings Time Arrive
- Data collection gives insight into the importance of truck saturation and minimizing truck bunching Time Spot
- Truck and digger cycle times drastically effected by over and under trucking as well as bunching U-Turn Time Begins
- Strategies must be implemented to ensure saturation is correct whilst minimizing bunching (both pre and post
FMS installation). Causes
increased hang
- Ensure we have the truck hours to support maximum excavator saturation time queue if
- From FY18 MIC YTD productivity averages, it appears the data from the 29/1/2018 represents the average trucks don’t read
large excavator production hour breakdown rhythm of digger
- Improving truck saturation with FMS has the potential to increase digger load hours by 16% at PTM
- Hot seating truck operators significantly reduced digger downtime at PTM
- Digger delays reduced from 39.5 minutes to 4.25 minutes by hot seating trucks at crib 1 (PTM)
- Potential too add an additional productive hour per shift per dig unit by hot seating trucks at PTM
- High “Hang Time Queue” due to digger repositioning when double benching and trucks not “reading the
rhythm” of the digger
- Time lost due to digger waiting for trucks to move from queue to the position where reversing/spotting can begin
- Green operators increased spot time can promote bunching
- Suggest keeping green truck operators on low priority digger circuit
- Poitrel excavators had significantly higher “Hang Time Queue” than Daunia but less “Hang Time True”
- Trucks are therefore waiting at the digger between loads and there is minimal occurrence of the digger waiting for
trucks to arrive
- Likely due to excavator repositioning and or pulling material from walls while truck/s are in queue
- Daunia likely to have higher true hang time due to being truck constrained. This may result in less “Hang Time
Queue” due to being able to reposition whilst waiting for trucks
BMC Time and Motion Study
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 Summary – Large Excavator Production Time
PTM (RH340B) PTM (RH340B)
DNM (5600-6) DNM (6060) SWC (5600-6) 29/01/2018 30/1/2018 PTM (6060)
72% Sat. 97% Sat. 31/1/2018
2%
6%
26% 20%
31% 31% 19%
23%
53%
5% 60% 51%
65% 4% 12%
6% 8% 22% 63%
67% 8%
3% 8%
7%

SWC PTM PTM PTM

5600-6 RH340B RH340B 6060
12/1/18 29/1/18 30/1/2018 31/1/2018
Shift Productivity bcm/hr. (day of 1616 1574 2403 1816
manual data collection) (MIC) (MIC) (MIC) (MIC)
MIC FY18 YTD Average Productivity 1700 (+5%) 1545 1545 1478
per Shift bcm/hr. (difference to day of (-2%) (-36%) (-19%)
collection)
BMC Time and Motion Study

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Summary – Truck Cycle Time Breakdown
PTM Terex RH340B Truck PTM Terex RH340B Truck
DNM Hit EX5600- Truck DNM CAT 6060 Truck SWC Hit. EX5600-6 Truck Cycle Time Breakdown Cycle Time Breakdown
Cycle Time Breakdown Cycle Time Breakdown Cycle Time Breakdown (29/1/2018) (30/1/2018)
(Nov-Dec FY18) (Nov-Dec FY18) (12/1/18) 5 Trucks on Circuit – 72% 6 Trucks on circuit - 95%
Sat. Sat.
6% 2% 7% 2% 11%
5%
2% 18% 16%
7% 6% 2% 3%

15%
21%
65% 60%
86% 86% 82%

DNM Hit EX3600 Truck SWC Hit. EX3600 Truck PTM CAT 6060 Truck Cycle
Cycle Time Breakdown Cycle Breakdown Time Breakdown
(Nov-Dec FY18) (11/1/2018) (31/1/2018)
9%
3% 18% 2%
12%
4% 2%

18%
19% 61%
68%

84%

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Poitrel EX36 Delays

• Significant EX36 delays on 29/01/2018 due to waiting for trucks at crib PTM EX36 Shift Delays (Crib 1 to Crib 2)
• 39.5 minutes between excavator operator crib 1 hot seat and 1st truck 29/01/2017
returning from crib 1

• Crib 2 timeline
• Trucks sent for crib 2 and excavator repositioned 0:12:43

• Refuelling commenced (31 minutes)

• Excavator then waited for 13 minutes for trucks to return from crib
0:39:26
• 3 trucks loaded

• Excavator operator then hot seated

0:30:46
• Crib break delays could be reduced by:
• Hot seating and or staggering truck operator crib breaks

• Improved timing/alignment of truck and excavator crib breaks

0:01:12
 2 trucks and EX36 operator were hot seated simultaneously on the
Waiting for Trucks at crib 1 Grader Clean Up
30/1/2017 which reduced delay to 4.25 minutes
Refuelling Waiting for Trucks at crib 2

BMC Time and Motion Study

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 BMC Improvement Opportunity – Large Excavators
SWC
Potential
SWC DNM PTM Value
Improvement
with FMS
Fcast FY18 (F06) Large Excavator Average Large Excavator Productive Hours/shift (FY18
Waste Hours
9793 YTD MIC)
8.33

5,190 6365
Derived Waste Load Hours
(53%) (65%) ↑1175 Additional Large Excavator Productive Hours/shift
(by hot seating trucks)
1

Fcast (F06) Total Large Excavator 16,370 k

Waste Movement (bcm) bcm ↑3.5M* New Large Excavator
Productive Hours/shift
9.33
YTD Waste Dig Rate
(Instantaneous) 2991 Derived Additional Load Hours/annum/load unit
(bcm/load hr.) (by improving truck saturation with FMS and hot seating–
increasing load hours from 51% to 67% of production
117
Fcast FY18 (F06) Large Excavator
Coal Hours
671 671 time)
Derived Dig Rate (30/1/18)
Derived Coal Load Hours 356 436 ↑80 @ 67% load hours
3587

Fcast (F06) Total Large Excavator

840 kt ↑0.21M
Coal Movement (t)
Derived Additional Waste Movement/annum/machine 420
(117*3587)
YTD Coal Dig Rate (Actual)
2566 Kbcm
(bcm/load hr.)

*𝑾𝒂𝒔𝒕𝒆 𝒎𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝒊𝒎𝒑𝒓𝒐𝒗𝒆𝒎𝒆𝒏𝒕 = 𝒀𝑻𝑫 𝑾𝒂𝒔𝒕𝒆 𝑫𝒊𝒈 𝑹𝒂𝒕𝒆 𝑨𝒄𝒕𝒖𝒂𝒍 × 𝑨𝒅𝒅𝒊𝒕𝒊𝒐𝒏𝒂𝒍 𝒘𝒂𝒔𝒕𝒆 𝒍𝒐𝒂𝒅 𝒉𝒐𝒖𝒓𝒔 𝒊𝒏𝒄𝒓𝒆𝒂𝒔𝒊𝒏𝒈 𝒍𝒐𝒂𝒅 𝒕𝒊𝒎𝒆 𝒕𝒐 𝑫𝑵𝑴 𝒂𝒗𝒆𝒓𝒂𝒈𝒆
BMC Time and Motion Study = 𝟐𝟗𝟗𝟏 × 𝟏𝟏𝟕𝟓 = 𝟑. 𝟓𝑴 𝒃𝒄𝒎
5/02/2018 10
Recommendations for FMS Transition
- Follow the truck allocation and reallocation strategy in Playbook 2.0
- Use saturation curve algorithm to maximize overall volume

- Execute trucking strategy to optimise haulage requirements to aid delivery of the 24 hour plan

- Ensure the business is focusing on both hang a queue time reduction at SWC and PTM after FMS Go Live
- Daunia focus mainly on queue time

- Create visual aids that are aligned to critical KPI’s to aid in decision making within IROC

- Ensure FMS is correctly set up including accurate mine model, dig units and truck unit correctly set up
- Conduct activities such as refuelling concurrently with hot seat changeovers to put delays in parallel
- Ensure we have the truck hours to support digger saturation across entire fleet
- Collect additional queue data at dump and ROM
- Identify any potential bottleneck processes with the likely production increase post FMS transition
- Do we have enough dozers to support additional waste dumping?
- Do we have sufficient ROM inventory to support additional coal mining?

BMC Time and Motion Study

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Recommendations for FMS Transition
- Develop an operator scoreboard and provide posters in the crib hut of performance
- Track operators KPI’s - Best performing operators can be identified and can provide training to others

- Important to select the correct KPI’s to track and post at crib hut – KPI’s that will not hinder safety

- Scoreboard will likely provide an uplift in operator performance and improve culture
- Feedback from operators over the course of data collection indicates they like the idea of a score system/ FMS performance track

- It will allow operators to be accountable for their own continuous improvement

- Will likely boost the confidence of green operators as they see their results improving

- Crew and shift performance can be compared to highlight the need for additional training etc.

- Operators indicate that:

- The friendly “competition” will likely improve performance of the teams
- It will improve the culture whilst ensuring they are focusing on safety (track corner speeds, boom stresses etc *If possible*)
- Will allow operators and teams to be accountable

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Daunia Loader Operator Performance Tracking Example

BMC Time and Motion Study

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Daunia Operator Scorecard – CI Expo

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Questions?

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My time at BHP
During my 3 months internship with BHP:

I’ve been
accountable for I’ve been given a
project/s and number of exciting
reporting opportunities to
develop key skills Worked with an
essential to my career awesome team! Been proud to be a
part of the BHP
culture

Potential Improvements for future interns:

Provide them with Provide more regular

contact details of other updates in regards to
interns prior to start relocation etc. prior to
date start date
Pre-read Materials
Shift Summaries
Data Analysis
Data Sources
Definitions

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17
5/02/2018
Benchmarking Performance - Purpose

• This study aims to provide the following:

• A benchmark of current performance, in absence of a fleet management system at both BMC operations (Poitrel and South Walker Creek
Mines). KPI’s include:
- Truck cycle times including queue, spot, load and travel/dump
- Dig unit cycle times including loading and hang time
- Delays including shift change, crib breaks, waiting on equipment, maintenance etc.
• Comparison of current BMC performance with active FMS BMA sites such as Daunia
• The definitions of cycle time elements such as hang time used within BHP for reporting
- Align BMC’s definitions and reporting practices with the rest of the asset
• Quantify the accuracy of current data collection processes such as MIC, VIMS etc.
• Identify value adding, improvement opportunities within the asset

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Data Sources
SWC PTM BMC

KPIs KPIs KPIs

PTM Comparison
SWC PTM PTM
MIC
VIMS Payload
Manual Time Haulage
Manual Time
Value Adding
and Motion
Data SWC and Motion Data Opportunities
TUM Data (Excel
PTM
Recorder)
Truck Cycles Truck Cycles
VIMS & MIC
SWC Collaboration
Delays iTrack Truck Idle DNM
(YTD) All Diggers Delays
Reports FMS
Digger Cycles Truck Cycles Digger Cycles Benchmark
(Load and (Load and Hang)
Hang) Digger Cycles DNM
Shift Production Corvus
Shift Production Hours
Production SWC Hours Reports
Hours MIC Productivity
Productivity Productivity
SWC DNM
Productivity
December APR Nov-Dec 17
PTM
FMS Data

BMC Time and Motion Study December APR

5/02/2018 19
Hitachi EX5600-6
Analysis
SWC EX12 – Data Collected 12/1/2018
From pre-start until Crib 1.

Daunia EX58 – Data obtained from

Minestar FY18 November
& December 17.

20
Excavator Performance (YTD vs. Day of Data collection)
SWC EX12 MIC YTD Productivity
35
30
25
Frequency

20 - Day of data collection

15
10
5
0

Waste Productivity (bcm/hr.)

MIC Waste Productivity (bcm/hr.)

Day data collected Mean (% difference to Median Mode Standard
mean observed mean) Deviation
SWC 12/1 1616 1700 (+5%) 1742 (+7%) 1900 316
(+14%)
This is used to quantify if the data collected manually is an accurate representation of a typical shift

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EX12 Queue vs. Truck Cycle
SWC Truck Saturations Effect on Queue and Cycle Times
0:04:20
0:04:00
0:03:40
Queue Time (hh:mm:ss)

0:03:20
0:03:00
0:02:40
0:02:20
0:02:00
0:01:40
0:01:20
0:01:00
0:00:40
0:00:20
0:00:00
0:08:00 0:12:00 0:16:00 0:20:00 0:24:00 0:28:00 0:32:00
Truck Cycle Time (hh:mm:ss)

3 Trucks 4 Trucks 5 Trucks

• Started shift with the intent to have 4 trucks on circuit

• Truck un-scheduled maintenance meant 3 trucks were on circuit for 1:06:00 of shift time
• 4 Trucks were then on circuit until digger operator requested for additional 2 trucks due to increased hang times. However, only received 1.
• Queue times were low throughout shift, however hot seating and delays meant occasional bunching was occurring.
• Resulting in fluctuations in queue vs. hang time

BMC Time and Motion Study

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SWC EX12 Queue vs. Hang Time True
0:06:00
4 Trucks 5 Trucks 3 Trucks
0:05:30
0:05:00
0:04:30
0:04:00
0:03:30
0:03:00
0:02:30
0:02:00
0:01:30
0:01:00
0:00:30
0:00:00
0:00:00 0:01:00 0:02:00 0:03:00 0:04:00 0:05:00 0:06:00

• Queue Time less than 20 seconds can

Time Arrive
be considered 0.
• This queue time accounts for the
time taken for the truck to make a
U-turn to be in position to start U-Turn Time Difference = Queue Time
reversing.

Time Start Reversing

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SWC EX12 Queue vs. Hang Time True
3 Trucks 4 Trucks 5 Trucks
SWC EX12 – 12/01/2018
0:10:00

0:08:00
Time (h:mm:ss)

0:06:00

0:04:00

0:02:00

0:00:00
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76 79
Cycle

• High “True Hang Time” when 3 and 4 trucks on circuit due to time waiting on trucks to arrive – under trucked
• Hang time when 5 trucks on circuit likely due to truck bunching

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Hitachi EX5600-6 Shift Summary DNM (5600-6)
SWC
12/1/2018
26%
Shift Time Recorded 4:55:00
Total Production Delays 00:44:20
Production Time 4:10:40 5%
65% 4%
Total Hang Time 1:59:00
Hang Time Spot 0:19:53
Hang Time Queue 0:20:20 SWC (5600-6)
Hang Time True 1:18:47
Total Loading Time 2:11:40 31%

Total Loads recorded 80

53%
Average True Hang Time per load 00:00:59
8%

8%

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SWC EX12 Truck Saturation Breakdown
• Saturation Point and Saturation were calculated at varying times throughout the shift
• When 3,4 and 5 trucks were assigned

3 Trucks 4 Trucks 5 Trucks

Mean Standard Dev. Mean Standard Dev. Mean Standard Dev.
Total Truck
00:17:22 00:05:22 00:14:41 00:02:42 00:14:24 00:01:57
Cycle Time
Queue Time 00:00:41 00:00:37 00:00:30 00:00:35 00:00:58 00:00:57
Spot 00:00:18 00:00:05 00:00:15 00:00:05 00:00:14 00:00:09
Hang 00:01:38 00:03:03 00:01:21 00:01:40 00:00:45 00:01:09
Load 00:01:51 00:00:08 00:01:40 00:00:19 00:01:37 00:00:23
Saturation
4.8 4.7 5.7
Point
Saturation 63% 85% 87%
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EX5600 Truck Cycle Time Breakdown
DNM SWC
Average Cycle 00:19:02 00:14:46
Time
Travel Dump 00:14:57 00:12:03
Time
DNM SWC
Queue Time 00:01:45 00:00:49
9% 11%
Spot 00:00:31 00:00:15
3% 2%
4% Load 00:01:49 00:01:39 6%

82%
84%

Travel/Dump Queue Spot Load

Travel/Dump Queue Spot Load

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MIC Comparison/Validation
MIC Actual
Hrs % of Shift Hrs % of Shift
Load Time 11.5 96% 5.4 45%
Hang Time 0 0% 4.8 40%
Derived EX936
0.5 4% 1.8 15%
Delay
Total Haul Time 50.8
Haul Time per Truck 10.16 85% 7.7 64%

Derived Truck Delay 1.84 15% 3.4 28%

iTrack Idle Time

1.68
Avg.

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Hitachi EX3600
Analysis
Hitachi EX3600

Data Obtained from time and motion data

collection on Thursday 11th of January 2018
(Dayshift)

29
MIC Comparison/Validation
18
SWC EX936 MIC YTD Productivity
16
14
Frequency

12
10
8
6
4
2
0

Waste Productivity (bcm/hr.)

EX936 MIC FY18 YTD Waste Productivity (bcm/hr.)

Mean Mean (% difference to Median Mode Standard
(Day of Data observed mean) Deviation
Collection)
SWC 11-1 1093 842 (-23%) 831 (-24%) 800 (-27%) 351
This is used to quantify if the data collected manually is an accurate representation of a typical shift
BMC Time and Motion Study
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SWC EX936 Queue vs. Truck Cycle
Truck Saturations effect on Queue and Truck Cycle Time
0:24:00
0:22:00
0:20:00
Queue Time (hh:mm:ss)

0:18:00
0:16:00
0:14:00
0:12:00
0:10:00
0:08:00
0:06:00
0:04:00
0:02:00
0:00:00
0:00:00 0:05:00 0:10:00 0:15:00 0:20:00 0:25:00 0:30:00 0:35:00 0:40:00
Truck Cycle Time (hh:mm:ss)

4 Trucks 3 Trucks

• Started shift with 4 trucks on circuit

• Truck was removed after 22 cycles due to increased truck queue at digger (over trucked)
• Removing truck reduced queue time and total truck cycle time but increased hang time later in shift due to a change in digging
conditions

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5/02/2018 31
SWC EX936 Queue vs. Hang Time True
Truck Queue Time vs. Digger Hang Time True
0:24:00
0:22:00
0:20:00
Truck Queue Time (h:mm:ss)

0:18:00
0:16:00
0:14:00
0:12:00
0:10:00
0:08:00
0:06:00
0:04:00
0:02:00
0:00:00
0:00:00 0:02:00 0:04:00 0:06:00 0:08:00
Hang Time True (h:mm:ss)

4 Trucks 3 Trucks

• 4 trucks on circuit has significantly larger queue time

• 3 trucks on circuit improved queue and hang times, however the spread of data increased due to spacing of trucks on circuit.
• Inconsistent truck spacing (bunching) resulted in the loading of the first truck in bunch giving increased hang time.

BMC Time and Motion Study

5/02/2018 32
SWC EX936 Queue vs. Hang Time True
SWC EX936 - 11/01/2018
4 Trucks on circuit
0:24:00
0:22:00
0:20:00
3 Trucks, >6 passes
0:18:00 3 Trucks, 6 passes
0:16:00
Time (h:mm:ss)

0:14:00
0:12:00
0:10:00
0:08:00
0:06:00
0:04:00
0:02:00
0:00:00
1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81
Cycle
Queue Hang

• NB: Cycles effected by delays were removed

• 25% of the shift indicates over trucking

• Occurrences of low queue high hang represent a cycle which the digger was waiting for trucks to arrive

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5/02/2018 33
EX936 Shift Summary
SWC SWC EX3600 DNM EX3600
Production Time Production Time
Shift Time Recorded 7:10:45
Breakdown Breakdown
Production Delays 00:46:49
Production Time 6:23:56 21%
29%
Total Hang Time 2:22:09
Hang Time Spot 0:30:05 8% 56%
Hang Time Queue 0:30:09 63%
8% 11%
4%
Hang Time True 1:21:22
Total Loading Time 4:02:40
Total Loads recorded 84
Average True Hang Time
00:00:58
per load

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5/02/2018 34
Truck Saturation Breakdown
• Saturation Point and Saturation were calculated at varying times throughout the shift
• When 4 trucks were assigned

• When 3 trucks were assigned and passes > 6

• When 3 trucks were assigned and passes < 7

4 Trucks 3 Trucks, 7 Passes 3 Trucks, 6 Passes

Mean S.D Mean S.D Mean S.D
Total Truck Cycle
00:22:52 00:05:28 00:14:18 00:03:38 00:13:05 00:01:14
Time
Queue Time 00:08:02 00:05:28 00:01:22 00:02:47 00:01:14 00:01:08
Spot 00:00:18 00:00:14 00:00:22 00:00:25 00:00:16 00:00:05
Hang 00:00:04 00:00:19 00:01:15 00:01:43 00:01:35 00:02:04
Load 00:03:54 00:01:02 00:02:34 00:00:34 00:02:25 00:00:15
Saturation Point 3.9 3.7 3.2
Saturation 105% 81% 94%

• When passes changed to 6, Queue + Spot + Load was reduced by 23 seconds. However, total truck cycle time reduced by 1 minute 13
seconds. Suggests a reduction in loaded travel time due to under loading.
BMC Time and Motion Study
5/02/2018 35
EX3600 Truck Cycle Time Breakdown
DNM SWC
Average Cycle 00:21:42 00:15:07
Time
Travel Dump 00:14:58 00:08:54
Time
Queue Time 00:01:54 00:02:56
DNM SWC
Spot 00:00:55 00:00:21

Load 00:03:55 00:02:55

18% 18%

2%
4%

9%
19% 61%
69%

Travel/Dump Queue Spot Load Travel/Dump Queue Spot Load

BMC Time and Motion Study

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Terex O&K RH340B
Analysis
PTM EX36
Data Obtained from time and motion data
collection on the 29th and 30th of January
2018 (Dayshift)

37
PTM EX36 Performance (YTD vs. Day of Data collection)
PTM EX36 MIC YTD Productivity
20
18
16
14
Frequency

12 - Day of data collection

10
8
6
4
2
0
50

1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
2000
2050
2100
2150
2200
2250
2300
2350
2400
2450
2500
2550
2600
2650
2700
2750
2800
2850
2900
2950
3000
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
Productivity (bcm/hr.)

Waste Productivity (bcm/hr.)

Day data collected Mean (% difference to Median Mode Standard
mean observed mean) Deviation
29/1/2018 1574 1544 (-2%) 1518 (-3%) 1350(-14%) 341
30/1/2018 2403 1544 (-36%) 1518 (-37%) 1350 (-44%) 341
This is used to quantify if the data collected manually is an accurate representation of a typical shift
29/1/2018 shift likely to accurately represent a typical FY18 YTD shift for EX36
BMC Time and Motion Study
5/02/2018 38
EX36 Shift Summaries 29/01/2018 30/01/2018
3 Trucks on 4 Trucks EX36 PRODUCTION TIME
Circuit on Circuit
BREAKDOWN (29/01/2018)
Start of data collection 10:33:01 8:47:15
20%
End of data collection 14:35:00 11:37:30
Total Shift Time Recorded 4:01:49 2:50:15 51%
22%
Production Delays (during recorded
01:24:07 00:08:02
production time)
7%
EX Production Time 2:37:52 2:42:13
EX36 PRODUCTION TIME
Total Hang Time 1:16:57 00:53:30 BREAKDOWN (30/01/2018)
2%
Hang Time Spot 00:10:30 00:18:51
19%
Hang Time Queue 0:34:03 00:31:32
Hang Time True 0:32:24 00:03:07
Total Loading Time 1:20:59 1:48:43 12%

67%
Total Loads recorded 50 62
True Hang Time per load 0:00:39 00:00:03
Horn to Horn Hang Time per Load 0:01:32 00:00:52
BMC Time and Motion Study
5/02/2018 39
 EX36 Performance - Waste
Queue vs. Hang Time True (Time digger waiting for
truck to arrive)
Date Load Time % of Recorded 0:12:00 PTM EX36 – 29/01/2018 – 3 Trucks on Circuit
0:10:00

Time (h:mm:ss)
Avg. Shift Double High hang due to trucks returning from
0:08:00
Benching 0:06:00
crib staggered

29/1/18 00:01:38 76% 0:04:00

0:02:00
30/1/18 00:01:45 27% 0:00:00
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49
Cycles
Waste Load Time
30
0:14:00 PTM EX36 – 30/01/2018 – 4 Trucks on Circuit
0:12:00
25 Large Queue due to

Time (h:mm:ss)
0:10:00 truck doing a loop
20
Frequency

0:08:00 and joining back of Trucks and Excavator Hot seat

15 queue after poor
0:06:00
10
0:04:00
spot attempt
5 0:02:00
0 0:00:00
1 4 7 10 13 16 19 22 25 29 32 35 38 41 44 47 50 53 56 59 62 65
Cycles
Time (h:mm:ss)
Queue Hang Time True
29/1/2018 30/1/2018

BMC Time and Motion Study

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EX36 Waste Circuit – Truck Performance
Truck Spot Time Truck Cycle Time Truck Cycle Breakdown EX36
14 6 Circuit
12 5
29/1/2018

Frequency
10 4
Frequency

8 3 2%
2
18%
6
4 1

2
0 15%

0:07:00
0:07:20
0:07:40
0:08:00
0:08:20
0:08:40
0:09:00
0:09:20
0:09:40
0:10:00
0:10:20
0:10:40
0:11:00
0:11:20
0:11:40
0:12:00
0:12:20
0:12:40
0:13:00
0:13:20
0
100%
Time (h:mm:ss)
Time (h:mm:ss)
29/1/2017 30/1/2018
29/1/2018 30/1/2018
29/1/2018 30/1/2018
3 Trucks on Circuit 4 Trucks on Circuit Truck Cycle Breakdown EX36
Average Stand. Dev Average Stand. Dev Circuit
30/1/2018
Queue 00:01:22 00:01:26 00:02:20 00:02:03
3% 16%
Spot 00:00:13 00:00:05 00:00:18 00:00:14
Load 00:01:38 00:00:24 00:01:45 00:00:16 21% 60%
Travel/Dump/Travel 00:05:53 00:01:26 00:06:35 00:02:53
Total Cycle Time 00:09:06 00:01:26 00:10:58 00:02:55
Saturation (%) 72% 95% Travel/Dump/Travel Queue Spot Load

BMC Time and Motion Study

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CAT 6060
Analysis
PTM EX02
Data obtained from time and motion data
collection on the 31st of January
2018 (Dayshift)
Pre-start to Crib 1

42
PTM EX02 Performance (YTD vs. Day of Data collection)
PTM EX02 YTD MIC Productivity
35
30
25
Frequency

- Day of data collection

20
15
10
5
0
50
0

1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
2000
2050
2100
2150
2200
2250
2300
2350
2400
2450
2500
2550
2600
2650
2700
2750
2800
2850
2900
2950
3000
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
Productivity (bcm/hr.)

Waste Productivity (bcm/hr.)

Day data collected Mean (% difference to Median Mode Standard
mean observed mean) Deviation
31/1/2018 1816 1481 (-23%) 1482 (-23%) 1080 340
(-68%)

This is used to quantify if the data collected manually is an accurate representation of a typical shift

BMC Time and Motion Study

5/02/2018 43
EX02 Shift Summary – 31/1/18 6 Trucks on Circuit 5 Trucks on Circuit
Offside Loading 90% Double Benching
31/01/2018 0%
7%
Start of data collection 5:30:00 AM 18%

End of data collection 9:40:00 AM 25%

11%
Total Shift Time Recorded 4:10:00
60%
0:17:57
Production Delays 71% 8%
(Shift Change)
EX Production Time 3:52:03 Shift Average
Total Hang Time 1:25:38 6%

Hang Time Spot 0:19:57

23%
Hang Time Queue 0:52:57
Hang Time True 0:12:54
Total Loading Time 2:26:25 63%
8%
Total Loads recorded 96
True Hang Time per load 0:00:08
Horn to Horn Hang Time per Load 0:00:54
BMC Time and Motion Study
5/02/2018 44
EX02 Waste Performance – 31/01/2018
Queue vs. Hang Time True (Time digger waiting for
truck to arrive)
Trucks Load % of Recorded
0:08:00
on Time Shift Double 6 Trucks 5 trucks 5 Trucks & Double Benching
Circuit Avg. Benching
6 00:01:35 0%
0:06:00
5 00:01:30 90%

Waste Load Time 0:04:00

50
45
40
35
Frequency

30
25 0:02:00
20
15
10
5
0
0:00:00
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76 79 82 85 88 91 94
Time (h:mm:ss) Queue Hang

Ex repositioned to tail at cycle Grader and water cart working

14, increasing queue on ramp promotes bunching
BMC Time and Motion Study
5/02/2018 45
EX02 Waste Circuit – Truck Performance
Truck Spot Time EX02 Truck Cycle Breakdown
Truck Cycle Time 6 Trucks on Circuit
25
14
20 12
Frequency

Frequency
10
15
8
28%
10 6
4
5 2
0 0
59% 2%
12%
Time (h:mm:ss) Time (h:mm:ss)

6 Trucks on Circuit 5 Trucks on Circuit

5 Trucks on Circuit
Average Stand. Dev Average Stand. Dev
Queue 00:03:45 00:01:25 00:01:51 00:01:31 15%
2%
Spot 00:00:16 00:00:08 00:00:12 00:00:06
12%
Load 00:01:35 00:00:14 00:01:30 00:00:05
Travel/Dump/Travel 00:08:02 00:00:40 00:08:55 00:01:16 72%
Total Cycle Time 00:13:39 00:01:48 00:12:27 00:01:44
Saturation (%) 112% 80% Queue Spot Load Travel/Dump/Travel

BMC Time and Motion Study

5/02/2018 46
FMS Valuation Targets vs. Actual Performance

Actual Performance
Dec-15 Jan-18
Measure Units Target Previous Time and Feb-17 Current Time and
Motion Study Motion Study
Queue Time – PTM
Min/cycle 0.50 1.32 2.17 2
Fleet
Queue Time – SWC
Min/cycle 0.50 2.48 0.83 0.5 (EX12)
Fleet
Hang time - PTM Fleet Min/cycle 0.88 1.03 N/A 1.5
Hang time - SWC 1.5 (EX12)
Min/cycle 0.88 1.45 N/A
Fleet 2.3 (EX936)

BMC Time and Motion Study

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 Appendix
Supporting materials

BMC Time and Motion Study

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VIMS vs. Manually Collected Cycle Data Comparison
(PTM) 29/1/2018 EX36 30/1/2018 EX
31/1/2018 EX02
3 Trucks on Circuit 4 Trucks on Circuit
Average Average Average Average Average Average
(Manual) (VIMS) (Manual) (VIMS) (Manual) (VIMS)
Queue 00:01:22 - 00:02:20 - 00:02:20 -
Spot 00:00:13 - 00:00:18 - 00:00:13 -
Empty Stopped
00:01:35 00:01:27 00:02:38 00:02:15 00:02:33 00:03:42
Time
Load 00:01:38 00:01:34 00:01:45 00:01:42 00:01:31 00:01:53
Travel/Dump/Travel 00:05:53 00:07:05 00:06:35 00:06:46 00:08:42 00:07:39
Total Cycle Time 00:09:06 00:10:06 00:10:58 00:10:43 00:12:47 00:13:14

BMC Time and Motion Study

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Definitions – Truck Cycles
Item Minestar
Triggered by the GPS location of the truck
passing through the assigned load units
Arrive Empty ‘Source Destination’ waypoint.
The Source Destination is the entrance to the
dig face that the chosen load unit is linked to
Start of Queuing First stop after entry to face destination
Start Spotting at
Last start after entry to face destination.
Digger (End of
Direction to be either forward or reverse.
Queuing)
Triggered by the VIMS sensors sending
information to Minestar to say that the struts
under the tray have registered a payload. This
Start of Loading
is usually after the second bucket.
(End of Spot)
Loading requires a status change of ‘Arriving
Empty’ to enable the status to change
automatically to loading
BMC Time and Motion Study
5/02/2018
Proposed Standard
From Draft conceptual cycle
Manual Data Collection definitions - FMS
Triggered by arrival at a source
When a truck arrives at a GPS point defined by
location near the dig unit (100m) configuration standard (source
entry point)– 100m from dig unit
Triggered by arrival at source
When a truck arrives at a entry point when loading unit is
location near the dig unit (100m) in ‘loading’ state or on delay (in
(Arrive Empty) which case the truck should go
into delay)
Triggered by previous truck being
loaded “start of travel loaded’ or
When a truck arrives at a location
move from source entry point to
and direction changes to reverse.
loading GPS point when no
trucks being loaded
Triggered by truck entering
Truck receives first bucket of
within ‘loading zone’ (10m radius
material.
from bucket offset or tracks)
50
Definitions
Item Minestar Manual Data Collection Proposed Standard
From Draft conceptual cycle
definitions - FMS

Start of Travelling Triggered when the trucks GPS location is 25m

Triggered when truck moves
Loaded (End of away from the dig unit location (last bucket When truck receives last bucket.
away from loading zone (10m?)
Loading) location).
When truck arrives at dig unit for When truck arrives at dig unit
End of Cycle When truck arrives at dig unit for next load.
next load. for next load.

Hanging time starts when the truck finishes When ‘loading’ ends and not on When ‘loading’ ends and no
Start of Hanging
‘Loading’ state and changes to ‘Travel Loaded’. delay. truck queuing , and not on delay

Hang time stops when the truck cycle state When loading begins, or truck
End of Hanging When ‘loading’ begins
changes to ‘Spot at Source’. * arrives empty, or delay begins.

• Dig Unit Production time is currently reported at BMC as:

𝐷𝑖𝑔 𝑈𝑛𝑖𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒 = 𝑆ℎ𝑖𝑓𝑡 𝑇𝑖𝑚𝑒 − 𝐷𝑒𝑙𝑎𝑦𝑠
• This data is collected by radio communications to collect times of first load and machine hours with SME operators.
• There is currently no reported hang time
• Therefore, reported production time assumes hang time = 0

* Daunia Hang Time Reported in this presentation includes truck spot time as advised by IROC
BMC Time and Motion Study
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Truck Saturation Breakdown

• Saturation is a concept used to measure the performance of a circuit

• The Saturation Point of the loading unit is the count of how many trucks, if perfectly spaced, could be accommodated by a
loading unit before over trucking (queue) is inevitable.
• It is the point at which a loading unit would have zero queue and hang, provided each truck was perfectly spaced.

• Saturation Point is expressed as:

𝑇𝑟𝑢𝑐𝑘 𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒 𝑛𝑜𝑡 𝑖𝑛 𝑑𝑒𝑙𝑎𝑦𝑠 − 𝑄𝑢𝑒𝑢𝑒
𝑆𝑎𝑡𝑢𝑟𝑎𝑡𝑖𝑜𝑛 𝑃𝑜𝑖𝑛𝑡 𝑜𝑓 𝐷𝑖𝑔𝑔𝑒𝑟 =
𝐿𝑜𝑎𝑑𝑖𝑛𝑔 𝑈𝑛𝑖𝑡 𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒 𝑖𝑛𝑐. 𝑑𝑒𝑙𝑎𝑦𝑠 − 𝐻𝑎𝑛𝑔

• As loading and travel times change throughout a shift, the saturation point for each circuit will fluctuate
• Saturation is the measure of how many trucks are currently assigned to a dig unit compared to the maximum number of trucks
that could be serviced (saturation point) before over trucking occurs.
𝑨𝒄𝒕𝒖𝒂𝒍 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑻𝒓𝒖𝒄𝒌𝒔 𝒊𝒏 𝑪𝒊𝒓𝒄𝒖𝒊𝒕
𝑺𝒂𝒕𝒖𝒓𝒂𝒕𝒊𝒐𝒏 % =
𝑺𝒂𝒕𝒖𝒓𝒂𝒕𝒊𝒐𝒏 𝑷𝒐𝒊𝒏𝒕

BMC Time and Motion Study

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Truck Saturation BMA Study – Playbook 2.0
• The drivers behind our historical performance in relation to Truck &
Shovel fleets have typically been:
• Production Rate (BCM/hr) – which delivers our total volume
moved;

• Queue (duration) or (%) of time – specifically for trucking fleets;

and

• Hang (duration) or (%) of time – specifically for loading unit (also

expressed as ‘Coverage %’).

• Figure 1 illustrates the data for shovel loading units both FY16 and
FY17 in relation to saturation.
• 62% of shifts throughout this period were greater than 100%
saturation, which presents itself in many forms of queue
scenarios experienced by operations;

• Large spread of results during this period, which indicates a high

level of variability in performance and no effective measures to
control; and

• Productive rate flat lines as Saturation increases, proving there

is a lower return of value as we over-truck or incur queue on
circuits.
*Extract from Daily Production – Truck Allocation Methodology*
BMC Time and Motion Study
5/02/2018 53
Daunia Playbook 2.0 Truck Saturation Comments
- Hang time reported by DNM is recorded as “Hang
Time True” and is the actual time the loader is waiting
for the truck.
- Little attention is paid to Hang Time at DNM and
instead the business has been focusing on queue
time.
- There is no budgeted hang time % that is accepted.
- Minestar has a warning set up after 180 seconds in
hang.
- A trucking strategy will be implemented as part of
Playbook 2.0 that considers the saturation of loader
units.
- Achieve a minimum of 70% saturation for individual
circuits;

- Minimise occurrences of greater than 100% saturation

for all circuits; and

- Overall Saturation for the shift greater than 70% for

80% of the shift for all circuits.

BMC Time and Motion Study

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Details of Data Sources
Source
Manual Time and Motion Data
SWC TUM Data (Excel
Recorder)
SWC iTrack Truck Idle
Reports
MIC Haulage Productivity
(Spotfire)
VIMS Payload (Spotfire)
MIC Haulage (Spotfire)
December Asset Performance
Report (APR) FY18
DNM FMS Data and Corvus
Reports
BMC Time and Motion Study
5/02/2018
Details
Manually entered cycle and delay data using Excel spreadsheet
Gives: Truck and Loader Cycles with breakdowns
Equipment Time Usage Data Record
Shift reports containing truck parked durations and locations
Shift summaries of load and haul times and volumes/tonnages for
excavators (PTM & SWC)
PTM truck cycle time and payload data
Shift summaries of truck haul times and volumes for assigned dig unit (PTM
and SWC)
FY18 asset performance – 6 months of actuals & 6 months of forecast
Daunia Minestar data – trucks cycles, dig unit cycles etc.
55
BMC Time and Motion Study
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