11

Beltana DevelopmentBeltana Development

22

Beltana OverviewBeltana Overview

Process Control Process Control

Continuous ImprovementContinuous Improvement

SummarySummary

33

Beltana MG1 to 4Beltana MG1 to 4

44

BeltanaBeltana

Located near Singleton.Located near Singleton.

Started in December 2001.Started in December 2001.

Set up as Individual Set up as Individual Business Units.Business Units.

55

BeltanaBeltana

Total of Total of 2121 Million tonnes Million tonnes mined to date.mined to date.

Total of Total of 7070 km of roadway km of roadway driveage to date.driveage to date.

66

Beltana DevelopmentBeltana Development

Drive 3.0m x 5.4m roadways.Drive 3.0m x 5.4m roadways.

Install 4 x 1.8m roof bolts with Install 4 x 1.8m roof bolts with mesh @ 1.5m spacings.mesh @ 1.5m spacings.

Install 2 x 1.2m rib bolts per 1.5m Install 2 x 1.2m rib bolts per 1.5m and once depth of cover exceeds and once depth of cover exceeds 175m 4 x 1.2m rib bolts per 1.5m.175m 4 x 1.2m rib bolts per 1.5m.

77

Equipment UsedEquipment Used

Single Miner Unit with:Single Miner Unit with:

– 1 x 12cm12.1 x 12cm12.

– 2 x 10SC32 Shuttle cars 16 tonne 2 x 10SC32 Shuttle cars 16 tonne pay load.pay load.

– Stamler Breaker Feeder. (1700tph)Stamler Breaker Feeder. (1700tph)

88

Process ControlProcess Control

Beltana is set up as 3 Business Beltana is set up as 3 Business Units that stand alone and are Units that stand alone and are aligned to a process.aligned to a process.

– Development Development

– LongwallLongwall

– ServicesServices

99

Organizational ChartOrganizational Chart

Operations Manager

Longwall Coordinator

Development Coordinator

Production Coordinator

Development Engineer

Development Planner

Crew Supervisor

Maintenance Supervisor

Crew

Services

1010

DevelopmentDevelopmentLeadershipLeadership

Development Development EngineerEngineer

DevelopmentDevelopment

CoCo--ordinatorordinator

Development Development PlannerPlanner

Development Development ProcessProcess

Development Development EngineerEngineer

DevelopmentDevelopment

CoCo--ordinatorordinator

Development Development PlannerPlanner

Development Development ProcessProcess

1111

Process ControlProcess Control

Development team responsible for everything.Development team responsible for everything. ..– People People – Production / Maintenance StrategiesProduction / Maintenance Strategies– Materials / SparesMaterials / Spares– Process ImprovementProcess Improvement– Short term planShort term plan– CostsCosts– RebuildsRebuilds– BudgetsBudgets

The Process is not Operations and not The Process is not Operations and not Engineering it is Development.Engineering it is Development.

1212

Process ControlProcess Control

Crew Supervisors run their Crew Supervisors run their shift and are accountable to shift and are accountable to the Development Coordinator.the Development Coordinator.

Undermanager's do not fill a Undermanager's do not fill a traditional role.traditional role.

1313

Crew LeadershipCrew Leadership

Maintenance Maintenance SupervisorSupervisor

Crew Crew SupervisorSupervisor

Technicians & Technicians & TradesTrades

Development Development ProcessProcess

Maintenance Maintenance SupervisorSupervisor

Crew Crew SupervisorSupervisor

Technicians & Technicians & TradesTrades

Development Development ProcessProcess

1414

Process ControlProcess Control

Crew Supervisor’s have 12 men Crew Supervisor’s have 12 men in their crew.in their crew.

One being a Maintenance One being a Maintenance Supervisor.Supervisor.

1515

Process ControlProcess Control

Crew’s are responsible and Crew’s are responsible and accountable for everything accountable for everything inbye the portal.inbye the portal.

Contractors are used for roads Contractors are used for roads and stoppings only.and stoppings only.

1616

Beltana prides itself for Beltana prides itself for sustainability.sustainability.

If a key person is out of the system If a key person is out of the system then the process is sustainable.then the process is sustainable.

This is achieved by growing from This is achieved by growing from within.within.

Process ControlProcess Control

1717

This is both formal and informal but is This is both formal and informal but is looked at as a part of the culture.looked at as a part of the culture.

You can’t manage what you don’t You can’t manage what you don’t measure.measure.

This is achieved by planning involving This is achieved by planning involving the people, the people, implementing, implementing, measuring,measuring, reviewingreviewing and re-measure. and re-measure.

Continuous ImprovementContinuous Improvement

1818

Shift Start meetings.Shift Start meetings.

Shift reviews.Shift reviews.

Weekly Plan / Reviews.Weekly Plan / Reviews.

Continuous ImprovementContinuous Improvement

1919

Continuous Continuous ImprovementImprovement

Panel Panel Reviews.Reviews.

Supervisors meetings.Supervisors meetings.

Hazard / Improvement Process.Hazard / Improvement Process.

Panel Standards / Audits.Panel Standards / Audits.

2020

Continuous Continuous ImprovementImprovement

Beltana went from 4 to 7 Million Beltana went from 4 to 7 Million tonnes per year.tonnes per year.

Development had to develop a Development had to develop a process which could maintain a 7 process which could maintain a 7 million tonne Longwall.million tonne Longwall.

The following evolved.The following evolved.

2121

Continuous Continuous ImprovementImprovement

70/30m System Single Miner Unit 70/30m System Single Miner Unit (12CM30) 4m/hr system.(12CM30) 4m/hr system.

70m 30m

100m Cycle Metres Cut Rate Production

Section Advance Section Advance

Days Per Cycle m/hr Shifts Hours Shifts

7.2 250 3.9 11 21.7 2.9

2222

Continuous Continuous ImprovementImprovement

100m Pillar Single Miner Unit (1 x 100m Pillar Single Miner Unit (1 x 2CM30’s) 4m/hr system. 2CM30’s) 4m/hr system.

12% improvement12% improvement..100m Cycle Metres Cut Rate Production

Section Advance Section Advance

Days Per Cycle m/hr Shifts Hours Shifts

6.4 230 4 9.5 17.6 2.2

2323

Continuous Continuous ImprovementImprovement

100m Pillar Super Unit100m Pillar Super Unit(2 x 12CM30’s) 5.8 m/hr system.(2 x 12CM30’s) 5.8 m/hr system.

40% improvement40% improvement100m Cycle Metres Cut Rate Production

Section Advance Section Advance

Days Per Cycle m/hr Shifts Hours Shifts

4.6 236 5.7 8.2 25.7 3.2

2424

Continuous Continuous ImprovementImprovement

100m Pillar Single Miner Unit100m Pillar Single Miner Unit(1 x 12CM12) 6.5m/hr system.(1 x 12CM12) 6.5m/hr system.

24 % improvement.24 % improvement.

Total Process Improvement 95%Total Process Improvement 95%100m Cycle Metres Cut Rate Production

Section Advance Section Advance

Days Per Cycle m/hr Shifts Hours Shifts

3.7 236 5.5 7.6 18.5 2.3

2525

Continuous Continuous ImprovementImprovement

People and the machines are the success to our process.

Due to the fact that people were involved, they selected and then owned the machines and the process.

2626

Continuous Continuous ImprovementImprovement

Ergonomics was a major Ergonomics was a major consideration in our machine consideration in our machine selection process.selection process.

The following slides show the final The following slides show the final result.result.

2727

12CM1212CM12

2828

ErgonomicsErgonomics

2929

10SC3210SC32

3030

Stamler Breaker FeederStamler Breaker Feeder

3131

Stamler Breaker FeederStamler Breaker Feeder

3232

SummarySummary

Our People are our No.1. Our People are our No.1. asset.asset.

We Control the whole Process.We Control the whole Process.

We are committed to detailed We are committed to detailed Planning.Planning.

3333

SummarySummary

The Process is owned by all The Process is owned by all stakeholders.stakeholders.

We strive for very high Standards. We strive for very high Standards.

High = Safe + High = Safe + ProductiveProductiveStandards PlaceStandards Place Place Place

3434

Beltana Single Beltana Single

Miner UnitMiner Unit

Maintenance

Pipe Extension

Retics / DCB

Section Advance

0