ACARP 2008

Improving Development Performance

2

ABM25s – From Plan to Production

• Background to Development at Ulan

• The plan to move development forward

• Why an ABM25s and ergonomic considerations and

modifications to the ‘standard’ ABM25s machine

• Implementation of machine underground

• Performance full year 2007 – how did we go?

• Plan looking forward – 2008 and beyond

Background

4

Ulan

5

Development Background

• Need to keep in front of new 400m ‘Fat Face’

• Long-term Ulan Development average of 224m per week

• Aiming for an average of 450m per week

– 12 months to double development rates

– Installing more primary and secondary support than

ever before on advance

6

The “Fat Face”

The Plan Forward

8

The Plan Forward

• Business identified that “Fat Face” meant less overall

development metres required for total Ulan reserve.

• Development needed to improve vastly in order to keep

up with expected and future planned extraction rates

• 224m kept up with old Longwall

• 450m per week required to keep up with new Longwall

9

The Plan Forward

• How do we double rates and total metres in 12 months?

• 2007 Development Plan

• All decisions centred around people

10

5 Milestone (5M) Project

11

2007 Development Plan

Quarter Target How?

Q1Additional operating hours

( Op Hours with no change to roster or calendar)

•Reduced Delays•Shorter Belt moves•Maintenance strategy•Operating strategy•Contingency planning•Panel Ownership

Q2 – Q3 Efficient use of Additional Hours ( MPOH = metres)

•Training•Process Improvement•Project Planning

Q4Effective use of increased metres( LW Bang for Development buck)

•Long-Term Planning•Mine design•Operating strategy

Why an ABM25s?

13

Why an ABM25s?

• Now Ulan is a mine that sees Development install:– minimum of 6 x 6’ roof bolts per metre

– 4 x 4’ rib bolts per metre equivalent

– Roof mesh modules

– Rib mesh modules

– 2 x 4m Jennmar Cables every 2m on advance 5m either side of all intersections on advance

– 150 x 8m Jennmar Cables in belt road before belt move

• Ulan is a ‘traditional’ cut-then bolt mine (Joy, DBT etc) – that is: a good cutting machine that can bolt

• Conditions now suit a Bolting Machine that can cut coal

14

Why an ABM25s?

• Development Rates

– Other Sandvik machines successfully employed at other mines

– Aiming for an average of 2.5 MPOH

– Current conventional machines best rates of 2 MPOH

• Workforce consultation with machine of choice

• People-based approach to all machine decisions

15

Why an ABM25s?

• Process undertaken to review machine options

– Joy 12CM30 (Condition/strata based) – currently have 2 x 12CM12

– DBT 30MB3 (Ulan already own one)

– ABM25 (or ‘s’ variant)

• Ultimately chose the ABM25s

– Ability to cut and bolt simultaneously

– ‘s’ variant a narrower machine (approx 8”)

– Breakaway’s, operator platform space, flitting, interaction

– Ergonomic improvements over other ABM machines

– Technology to expand in future (push button bolting etc)

Ergonomics

17

Machine Review

• Review conducted of older and newer ABM machines

– What did they already do well?

– What could be improved?

– What influence could we have on our people and the

interaction between “man and machine”?

– Where is the “line in the sand”?

• Ulan Improvements with assistance from Sandvik (OEM)

• View that Ulan was purchasing a miner, not a deadline

18

Ergonomic Considerations

• Ulan Improvements with assistance from Sandvik (OEM)

– Ventilation/Dust/Heat

– Bolting Area Layout

– Operator Platforms (Access, Hand Rails, Compliance)

– Bolting Consumables

– Machine Access (Past slip, trips, falls, ankles, knees etc)

– Adjustable Operator Platform Height (Production and Maint)

– Rib Mesh Holder/Locator

– Machine Area Lighting

– Operator Console

– On-Board Tensioners

19

Machine Leaving Workshop - Austria

20

Machine – Operator Platforms

Improved Operator Ergonomics and Work Space

21

Ventilation

Whale Mouth rubber extended 6” to inbye side of curtains to ensure dust at face through full movement of cutter boom

22

Ventilation – ‘Man Fans’

Hydraulic powered and adjustable ‘Man Fans’ fitted to both sides of machine (aids in humid panel conditions and to keep dust at face)

23

Bolting Area - Layout

Bolting Area Layout designed such that operator could bolt and not have to move

feet or need to rotate body from hips down, bend over, or reach around (ABM shoulder).

Bolting supplies are where needed

Hydraulic Roof Plate Holder

Chemical Box Holder

Drill Steel/Roof Bolt Holder

24

Bolting Area – Open Access

Two (large) operators can work comfortably side-by-side

25

Bolting Area – Open Access

Bolting Area Layout can easily accommodate two large operators working comfortably side-by-side. One clear benefit of the ‘s’ machine being 8” narrower.

26

Bolting Area – Open Access

Poly Steel Holder:

• 3 x roof bolts

• 1 x drill steel

(avoids steel laying in walkways or laying on head)

Layout of bolting area based on a

triangle

(reduce angle as much as possible)

27

Bolting Area – Open Access

Bolting Area fitted with rubber matting to reduce fatigue

Open Space and reasonably level platform

28

Operator Platforms – Open Access

Open and Clear access to work areas.

Noise attenuation panelling fitted to length of machine to reduce noise from hydraulic pump and pump motor.

Significant reduction in heat into operator area

29

Operator Platforms – Hinged Hand Rails

Hand Rails have been fitted with a hinged arrangement to allow greater walkway room.

Can be then folded in when flitting or completing a break-away.

30

Operator Platforms – Step/Handle

Large area at rear – potential to fall

ABM25 use vertical ladder to access machine

Stairway and handrails added

31

Operator Platforms – Step/Handle

Hand Rail provides the necessary ‘three-points-of-contact’ for compliant steps/ladders

Rear platform has been fitted with an arrangement so when folded up the hand-rail remains vertical.

Steps are then secured out of way

32

Operator Platform – Height Adjustment

Whole Operator Platform is height adjustable.

Allows operator to set platform working height to suit cutting height and/or operator height.

Avoids over-reaching strain injuries

Can raise/lock platform for easier access to under machine for maintenance

33

Roof Mesh Carrier – Slide/Twist

Mesh Carrier traverses machine down onto tail for loading mesh modules (x20 sheets)

Rotates either way – depending on side machine ventilated from

Supply Pod

Supply Pod

Roof Mesh Bundle

34

Rib Mesh Holder

Rib mesh holder fitted to rib shield.

Fitted in correct location/height for cutting profile, mesh sheet size and rib bolt location.

Encourages operator to use side shield

35

Machine Area Lighting

Improved area lighting along walkways, under tail, surrounding bolting areas, along ribs and at canopy/bolt level.

Lighting test completed as part of machine commissioning

36

Machine Roof Lighting - Canopy

37

Operator Console – Screen/Rib Borer

Operator Screen and Rib Bolting console designed to be at ergonomic level for screen viewing and handle heights.

Bolter controls angled to allow better view of rib bolter

38

Operator Console – Screen Mounting

Operator Screen is mounted on a pivot system.

Allows operator to move/tilt/turn screen to suit individual.

Screen mounted at eye-height.

39

Tensioner – On Board Intensification

On-Board Pressure intensification for cable bolt tensioning.

Does away with need for air hoses, foot pumps etc.

Mounted on machine in a locked steel enclosure .

Implementation

41

Implementation Plan

• Formal Implementation Strategy

– How to introduce to the mine

– How to engage people and align with goals

– How to convince workforce of machine benefits

• Implementation Plan

– How to implement machine to the U/G environment

– Implementation of the machine into panel operations

– Staged approach swapping from Joy to ABM

42

Implementation Plan

• Bulk of work completed before miner ever on site

– Risk Assessments

– Roadway clearances

– Regular crew talks and information sessions

– Involvement from workforce in machine build

– Operator/Trade involvement in all stages of machine

modification, testing and commissioning

– Panel processes and process management

Performance

44

Performance – Past 10 Years

YTD Development Metres 1997 to 2007 (Full Year)

13130 12780 12979 13265

11,706 11,313

20,040

12,23810030

9620

14372

0

5000

10000

15000

20000

1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

Year

To

tal M

etr

es (

YT

D)

45

ABM25s Performance

• Production commenced July 2007

• Aiming for a minimum average of 2.5 MPOH

• Achieved an average of 2.5 MPOH – peaks at 7 MPOH+

• Aiming to have 4 MPOH+ ongoing

46

Performance – Pillar Cycle Times (100m)

Pillar Cycle Times (100m)

0

20

40

60

80

100

120

140

160

180

200

17 18 19 20 21 22 23

Pillar Number

Ho

urs

(C

oa

l to

Co

al)

JOY 12CM30

ABM25s

JOY

ABM

47

Performance – Flit Times

ABM25s - CM7015 Flit Times

10

7

6

54.5

0

2

4

6

8

10

12

18 19 20 21 22

Pillar Number

Flit

Tim

e 'B

' - 'A

' (h

rs)

Flit Time (hrs)

Poly. (Flit Time (hrs))

48

Operating Reports

8.6min average cycle = 7 MPOH

49

Operating Reports

50

Operating Reports

51

Real-Time Machine Monitoring

52

Cutting Cycle – 9 Step

0.5m

0.5m

9 - Clean-up Run

1

2

3

4

5

6

7

8

9 Step Cut Cycle

• Step 1 to 4

• Step 5 to 8

• Step 9 – Clean

Options are programmed into Auto-Cut

3.1

m

53

Horizon Control

2008 and Beyond?

55

What Did 2007 Show Us?

• 2007 showed that Development:

– can do it!

– do some things very well

– can do other things much better

– can be more efficient

– can be cyclical in nature

– have good people and know how to “cut coal”

56

Development as a Business

• Development Operating System

– Operating strategy

– Maintenance strategy

– Robust Planning system - Authority to Mine

– Cost management

– HSEC

– Review Process

• For Development, we can have all the procedures and processes under the sun

• If no-one knows them or regularly audits them – may as well not have them.

Process

57

How Much Value do we Really Add?

Total Available Time

Scheduled Production Time

Available Operating Time

Reported Run Time

Net Run Time

Efficient Net Run Time

Value - Adding Time

24 x 7 = 168hrs p/w

Scheduled Down Time

Setup Time

Delays

Unrecorded Delays

Slow Spee

dReject

sRewor

k

Maintenance, Rosters

Belt Moves, Flits, Relocations

Breakdowns as per Deputy Reports

Supplies, Wait on Car, Vent Tube Ext, Sec Support

Proficiency, Speed of Bolters, Wheeling Roads, Miner Driver

Floor brushing/cleaning, trimming, pull back for additional support

58

How Much Value do we Really Add?

Total Available Time

Scheduled Production Time

Available Operating Time

Reported Run Time

Net Run Time

Efficient Net Run Time

Value - Adding Time

Scheduled Down Time

Setup Time

Delays

Unrecorded Delays

Slow Spee

dReject

sRewor

k

Metres per Operating Hour

Hidden Inefficiency

59

Tool to Improve…

Total Available Time

Scheduled Production Time

Available Operating Time

Reported Run Time

Net Run Time

Efficient Net Run Time

Value - Adding Time

Scheduled Down Time

Setup Time

Delays

Unrecorded Delays

Slow Spee

dReject

sRewor

k

Traditional Approach

Belt move improvement – 10 day cycle

24 to 14 hours (10 / 240 = 4% improve)

Different Approach

5% in all areas = 30% improvement

60

The Future – Vent/Services Mono Rail

Conclusion

62

Conclusion

• Project commenced 12 months ago to replace ageing

continuous miner fleet

• Development required a ‘step-change’

• Focus on how people relate to the machine, and how the

machine relates to the environment

• Recognising the value of measuring and continually auditing

• Recognition that people will ultimately ‘make or break’ any

amount of good work or equipment

63

Conclusion

Brilliant process management is our strategy.

We get brilliant results from average people managing

brilliant processes.

We observe that our competitors often get average

(or worse) results from brilliant people

managing broken processes”

Hajime Ohba, Toyota, 2007