ROADWAY DEVELOPMENT
“TEMPO” LEAN AT KESTREL
Rod Pike
Rod Graves
Superintendent Development Gateroads
Development Coordinator
TO IMPROVE IS TO CHANGE, TO BE PERFECT IS TO CHANGE OFTEN
Sir Winston Churchill
20 year old mine.
Highest profit returning business for Rio Tinto Coal Australia.
We have a young, energetic and mature workforce.
Tony Lennox had a focus on “good reputation” as a measure of success and good
reputation is built on principles and actions.
Lean Thinking is based on good principles and actions.
Farthing West has been assisting us to implement Lean at Kestrel.
Three areas of influence:
People
Behaviour - involvement in problem solving (ideas and actions)
Process
Users - Standardise and improve processes (end users)
Equipment
Processes and maintenance.
Its all about the people
Developing Worker Problem Solvers.
BACKGROUND
Kestrel Mine
KESTREL – A MINE TO BE PROUD OF
8
7
6
0
Oaky North
Newlands Northern
Beltana / Blakefield South
Mandalong
Crinum East
Kestrel
Ulan
North Wambo
Oaky Creek No1
Moranbah North
Grasstree
Broadmeadow
Angus Place
Dendrobium
Ravensworth
North Goonyella
West Wallsend
Appin / Appin West
Ashton
Springvale
West Cliff
Carborough Downs
Baal Bone
Austar
Metropolitan
United
Integra
Tahmoor
Bundoora
NRE Wongawilli
Million ROM tonnes
Kestrel - One of the top producing mines in Australia
And we do it with old equipment
Jul 2009 Jun 2010
10
9
Kestrel Top Three Slide
Coming from Robyn Ryan
5
4
3
2
1
Development
Longwall
(
Kestrel Longwall)
And we are working hard to make it safer
Source: Queensland Mines and Quarries
Safety Performance and Health Report 2008-09
SAFETY COMPARISONS
Kestrel – the best safety record in Australia.
In spite of more support, greater cross grades (now 1:11),
Typically weaker roof (less than 10 mpa) and high water intakes
8.5
18
8.0
16
7.5
14
7.0
12
6.5
10
6.0
8
5.5
6
Pillar Cycle Time in Days
average roof support density
MG310
MG309
MG308
MG307
4.0
MG306
0
MG305
4.5
MG304
2
MG303
5.0
MG302
4
average roof bolts per metre
20
MG301
average days per pillar
Pillar Cycle Time vs. Prim Roof Support Density
J
COMBINED OVERVIEW
Kestrel – Pillar cycle times improving.
OUR IMPROVEMENT TO DATE
WORKER PROBLEM SOLVERS
Overview
There are 3 documents that make up the suite
of tools for the panel advance :
• The Overview
• Detail Cards
• Check Lists
Note it is the intent to incorporate the trigger for issuing all
documents onto the panel sequence plan on the Lean Story
Board.
Detailed Card
Check List
PANEL ADVANCE TOOLS
3 Key Documents
Teams / parallel
tasking
Manning
Activity number
for reporting
Summary of
activity
Tools / materials
required
Reference
for details
Time in
blocks of
30 mins
Vehicle
READING THE OVERVIEW
Overview Card
The team breaks
up to do individual
tasks
STANDARD WORK CARDS
Teams Colour
Manning, vehicle
and expected time
Written in by
Team Leader
Read the card
and Do a Take 5
Detail on each
activity
Activity number
for reporting
Reference Name
Time activity
began – written in
by team leader
Expected elapsed
time at end of this
task
When management (ERZ
controller/supervisor, coordinator,
checks on
progress the focus is on
learning and improving. If
progress is lagging what
are the root cause issues?
superintendent etc)
FRONT OF STANDARD WORK CARDS
Front of Detail Card
Version and Date
of last revision
Tools / Material
needed
Sketch / picture
Colour legend
Team leader should provide feed back on the detail - times – sequence –
errors in instructions - omissions in instructions – safety improvements –
suggested new techniques – engineering mods etc
REAR OF STANDARD WORK CARDS
Rear of Detail Card
KAMISHIBAI CARD AUDITING
FLITTING
ROAD CLEANING
Face Road – wet and wheel rutted
Place Dry Coal or stowage
to start cleaning
Note if conditions are wetter tip the muck
from the bucket further forward over the heap
TECHNIQUE TO ROLL THE MUCK
Roll the muck heap and tip
Face Road – wet and wheel rutted
Tip load
CLEAN FROM DRIVERS SIDE TO OFF SIDE
Start on Driver’s
side and work across
heading
STANDARD CUTTING HEIGHT
HORIZON CONTROL TOOLS
Tilt table with level attached?
Guide to site seam profile?
21
STANDARDISED SUPPLY LOCATIONS
IMPLEMENTS
LEAN INFORMATION CENTRE
In spite of more support, greater cross grades (now 1:11),
weaker roof (less than 10 mpa) and high water intakes
8.5
18
8.0
16
7.5
14
7.0
12
6.5
10
6.0
8
5.5
6
5.0
4
Pillar Cycle Time in Days
average roof support density
MG310
MG309
MG308
MG307
MG306
MG305
MG304
MG302
0
J
4.5
KME is targeting more improvement.
A 10 day pillar cycles. 4.0
MG303
2
average roof bolts per metre
20
MG301
average days per pillar
Pillar Cycle Time vs. Prim Roof Support Density
COMBINED OVERVIEW
Kestrel – Pillar cycle times improving.
5% potential improvement from longer pillars
MODELLING LONGER PILLARS AND FASTER WHEELING
KME – longer pillars and faster wheeling.
307
308
309
307
Time to First Coal is averaging in excess of 4 hours per shift
after allowing for Panel Advances, mobilisation and
Maintenance days.
Typical best times are about 1 hour 20 mins
308
309
TIME TO FIRST COAL
Comments
307
In the order of 2.2 days per 28 days are lost for meetings
pass and training - the morning meeting accounting for a
significant portion of this time
308
309
MEETINGS / PASS / TRAINING
Comments
307
1.3 to 2.1 days per 28 days are lost with road cleaning. This
time probably understates the problem.
308
309
ROAD WORKS
Comments
CUTTING TIME
Presently
Only 6 days cutting every 28 days
Getting the crew away on time
Having the transports from pit bottom to the panels pre started
Controlling meeting times
Using between shifts and cribs to clean roads etc
Concentrating on horizon control to reduce the need to clean roads
Having tradesmen stay at the face to prove that the machine is producing correctly
Train outbye workers to assist in manning the miner during one of the two crib breaks
Staying at the face to cut till the end of the shift
Commence planning for overlapping shifts to improve maintenance window utilisation
CUTTING TIME 34 HOUR PER WEEK TO 50 HOURS
Multiple small steps
PILLAR CYCLE MODELLING MORE HOURS
Focusing of roster issues – 30% improvement
OUR IMPROVEMENT TO DATE AND OUR TARGET
PEOPLE / PROCESS / PERFORMANCE
6 Mths
Now
Past
THE GOAL IS ZERO
The Goal is Zero
Success with Pride
13 April 2015
36