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 Results - Underground Coal Mine (2)

Context / scope of project : This underground mine had been active for many years, and was reaching its end-of-life. As most of the “easy coal” had been mined out in previous years, geology had become very difficult with frequent dykes and inclined seams. The mine was facing significant water issues - combined with the inclined seams, underground conditions were extremely difficult, especially given that most of the fleet of continuous mining machines were at 300%+ of their recommended service life and thus prone to frequent breakdowns. Finally, it was well known that the current owners were planning to sell the mine, leading to severe morale problems and high personnel turnover. The brief from the mine was to improve profitability substantially, without capital expenditure.

PIP and client achieved:
28% decrease in costs per tonne of coal
35% tonnage increase in key production areas
29% reduction in main belt downtime
15% reduction in continuous miner downtime in key production areas




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What we did:

Value driver trees

Implemented ideas pipeline

Introduced Results Action Reviews (RARs) from GM level down to section/shift level
Short term (shift level) planning linked to weekly, monthly and quarterly mine plans
Root cause analysis, automated Pareto analysis for weekly RARs in maintenance
Extensive operator, supervisor and superintendent training
“Visual factory" to enhance shift handover effectiveness
Front-line coaching of personnel in key production sections
Coupled the RAR process to short-term planning


 
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