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| Underground Coal Management Operating System
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Context / Scope of project
Our client was an Australian mining operation with an open-cut and an underground mine producing metallurgical coal (semi-hard and semi-soft coking coal) and thermal coal.
The underground operations were consistently underperforming against production targets. Early assessment determined that by implementing a robust
MOS (Management Operating System) underground, performance-to-plan could be dramatically improved.
The MOS was supported by a customised software tool which automated:
- Task Planning/Scheduling (both in the mine and in maintenance)
- Sequencing
- Compliance Management
- Chain and time based triggers
- Resource management and Scheduling (ops and maintenance)
- Linkages between the mine plan and the ops and maintenance schedules
- Progress/status reporting
- Communication (between shifts and up/down the structure).
Client achieved:
- More detailed and comprehensive planning process
- Enhanced ability to react to change (within a shift, between shifts, over time)
- Greater role clarity and single point accountability
- Culture of stability and focus on productivity
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What we did:
- Created and syndicated Value Driver Trees (VDTs) for the business
- Created and syndicated site RACI to clarify roles and responsibilities
- Mapped Management operating system (mine planning, longwall, development, maintenance)
- Drove clarity and efficient execution across existing planning processes (Yearly, Quarterly, Monthly)
- Created and embedded additional and more detailed planning processes
- Supplied extensive coaching (underground, across all shifts and rosters) to embed new/improved processes
- Implemented “wiring”
- Short Interval Controls at the mine face
- Daily/Weekly Results Action Reviews (RARs)
- Shift Handovers
- Supervisory feedback loops
- Visual Boards
- “5 Whys” and RCA (Root Cause Analysis) tools
- Implemented “Ideas Pipeline” for Continuous Improvement of processes
- Identified and deployed KPIs at all levels (aligned to VDTs)
- Created, installed and trained automated planning/tracking tool underground.
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