Transcript Fleet Selection based on Target Production

Load and Haul Fleet Selection
Based on Fixed Plant Production
Load and Haul Fleet Selection
Based on Fixed Plant Production
Ways to Estimate Productivity !!
The typical view is machine centred …
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 !
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?
What is the Load Area
Production Rate ?
What is the Match of Loading
Tool and Haulers ?
What does our Reality look like?
How much of an Hour does the
Loading Tool spend Loading?
What are the Cycle Times for
Haulers and Loading Tool?
What is the Key Characteristic
of the Material?
Bunching and Cycle Mismatch
Quarry Contacts
• Queensland and Northern Territory
• Paul Soden
Hastings Deering,
Brisbane
WesTrac,
Sydney
William Adams,
Melbourne
William Adams,
Launceston
Cavpower
Adelaide
WesTrac
Perth
• New South Wales
• Andrew Black
• Victoria
• Ian Collins
• Tasmania
• Stuart Mc Donald
• South Australia
• Mark Taylor
• Western Australia
• Steve Sakich
Any Questions ?
The End
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
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
Work Hours Available per Year
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)
PRODUCTIVE TIME
6615 HRS
Machine Operating Hours
(6615 HRS)
Machine Scheduled Hours
(7350 HRS)
Mine Scheduled Hours
(8400 HRS)
Total Annual Hours
(8760 HRS)
735
HRS
10 %
of
7350
1050
HRS
12.5%
of
8400
360
HRS
4.1 %
of
8760
Work Days per Year
• Full Days
• Partial Days
• Partial Day Factor
220 days
48 days
0.50
Load & Haul Work Hours per Day
Load and Haul Scheduled Hours / Day 10 hours
less Non Operational Time
Mobilisation
Toolbox Talk - Inspect - Transit
Transit - Refuel - Shut Down
Breaks including Transit time
AM / PM Breaks
Lunch
Subtotal of Non Operational Time
20 minutes
20 minutes
20 minutes
45 minutes
1.75 hours
less Non Primary Load and Haul
Stock movement
Overburden
Subtotal Non-Primary Load and Haul
Work Hours per Day
0.75 hours
0 hours
0.75 hours
7.5 hours
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.
Operation
Day
Night
Working Hour
50 minute hour
45 minute hour
Efficiency
Factor
0.83
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 ?
Analysis of Face Loader Activity
Load Area Activity of Wheel Loader
Preparing to Load
17 %
Non-Loading
Activities
30 %
Predig Pile
8%
Loading Truck
54 %
Remove Oversize
17 %
Maintain Floor
2%
Clean Floor
3%
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
Density of Materials
Material
Gravel - pit run
Earth-dry
Earth- wet
Clay – natural bed
Topsoil
Shale
Granite -broken
Limestone
Full Table in
PHB 42 P27-4
Bank
kg/m 3
2179
1900
2020
2020
1370
1660
2730
2610
Loose
kg/m 3
1930
1510
1600
1660
950
1250
1660
1540
Load
Factor
.89
.80
.79
.82
.70
.75
.61
.59
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
Machine Production
CYCLE TIME
Operator Skill
LOAD
Fixed Time
RETURN
Variable Time
Delays
HAUL
DUMP
Variable Time
Fixed Time
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
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
Bucket Fill Factor (BFF)
Material
BFF as % of
Heaped Capacity
Moist Loam
Sand and Gravel Mix
Rock - Well Blasted
Rock - Poorly Blasted
12 –20mm Aggregate
ABC-
100-120 %
95-110 %
80 - 95 %
50 - 75 %
85 - 90
A
C
B
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
Quarry Contacts
• Queensland and Northern Territory
• Paul Soden
Hastings Deering,
Brisbane
WesTrac,
Sydney
William Adams,
Melbourne
William Adams,
Launceston
Cavpower
Adelaide
WesTrac
Perth
• New South Wales
• Andrew Black
• Victoria
• Ian Collins
• Tasmania
• Stuart Mc Donald
• South Australia
• Mark Taylor
• Western Australia
• Steve Sakich
Any Questions ?
The End