Lean Case Study -Rio Tinto - Kestrel Coal Mine Extension Project - Rev 2014

8/9/2019 Lean Case Study -Rio Tinto - Kestrel Coal Mine Extension Project - Rev 2014

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Kestrel Coal Mine Extension Project

KME, LEAN Case Study

A ‘LEAN’ Case Study

April 2014


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KME Project – LocationSunny Australia


Emerald

April 2014


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Background

• "ro#e$ted $ost 52+0 %illion

• Key Work Packages

6 T&in dri)ts, 1 ! Con7eyor, 1 ! Transport

6 Sin'in o) 8entilation Sa)t

6 Supply and install 8entilation )ans

6 "it 9otto( de&aterin prora(

6 "it 9otto( de7elop(ent o) (ine in)rastru$ture and lon&all panels

6 Constru$tion o) --0 (ea litre site storae da( and sedi(ent da(s

6 Constru$tion o) :'( $on7eyor to Kestrel

6 ;p rade o) C


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Drifts - Secifications

• Conveyor Drift

6 1-:: (etres lon at a radient o) 1@

6 Ar$ pro)ile +-( &ide ! 4+:-( i+

6 Con$rete se(ent )loor+

• Transport Drift

6 1=: (etres lon at a radient o) 1@=

6 Ar$ pro)ile +0( &ide ! 4+-( i+

6 Con$rete se(ent )loor+

April 2014 KME, LEAN Case Study


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Con7eyor >ri)t@ nterse$ts $oal sea(s

Drifts - Con!eyor



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Drifts - "ransort

Transport >ri)t BSupport $lass 1



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Drifts - Construction

• Tere a7e 9een 4 (etods o) $onstru$tion to date in ea$ dri)t+• Method 1:

6 %o! $ut e!$a7ated ten stru$tural $on$rete ar$es and )loor

se(ents $onstru$ted and 9a$')illed+

• Method 2:

6


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Drifts – Cut # $ill

Con7eyor >ri)t 6 Metod 1 Cut Dill April 2014 KME, LEAN Case Study


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Drifts - Construction

• Method :

• eote$ni$al e7aluation ten deter(ined te lo$ation to

dis$ontinue te steel sets and s&it$ to rins o) 2+4( )ull $olu(n

resin ro$'9olts installed &it a Fu(9o and :-(( o) )i9re

rein)or$ed sot$rete+ BD?S

• E!$a7ation $ontinued &it te ydrauli$ e!$a7ator )itted &it a

.ui$' it$ to allo& te use o) te 9u$'et or a ro$' 9rea'er+

BSupport $lass 2



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Drifts – Steel Sets

>ri)t Constru$tion 6 Metod 2 Steel Sets April 2014 KME, LEAN Case Study


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Mitsui S%&& 'oad (eader - Attac)*ents

Sot$rete 9oo(

Sot$reteControlsBS&in out

%olter

KME, LEAN Case Study April 2014


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Case Study – KME Drift Construction

Con7eyor >ri)t 6 Cut &it Mitsui S200 ?oad


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'oad (eader

?oad


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'oad (eader – Sliding $loor

Con7eyor %oot End

Con7eyor sendsMaterial to Sur)a$e

%r i d ,e C o n7 e y o r

"re Cast Con$rete )loor se(entsSlidin Dloor

8 ent >u$ t B E ! aust C

Clean air



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Drifts – Concrete $loors

Con$rete )loor se(ents

>ri)t Cross Se$tion



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"re$ast Con$rete )loor se(ent

Con$rete Ni9 6 "oured aead o)te slidin )loor

Sot$rete in)ill

Con$rete 9lindin

rout



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"re$ast $on$rete )loorse(ents

+0( ! 1+3( !-+2 Tonne

"la$e(ent &it L

rout in#e$tion oles



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Non slip e!posed areatesur)a$e

Se(ents in pla$e

Li)tin Lu

Ni9

%lindin Con$rete



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*ro!e*ent Cycle


et te )a$ts

"ro$ess Maps

nterroate >ataED; raps

>ri)ts(pro7e(ent

"lan

Con$ernStrips

Monitor

April 2014


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nterrogate t)e Data

&tart .p

$amiliarisation

&teady &tate/Clay

M+dstones

$irst Coal &eam

Water/ m+d/ floor iss+es

&andstone



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.isualise t)e Cycle

"ro$ess Maps Con7eyor >ri)t Cy$le Ti(es

•Cy$le ti(es are 7ital to our oalo) $ontinuous i(pro7e(ent

•Ea$ ele(ent o) ea$ $y$le asa taret ti(e tat as 9eenareed 9y te tea( as realisti$and a$ie7a9le



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Cycle "i*e Process Ma

reen 6 ;nder Ti(e, ?ed 6 G7er Ti(eKME, LEAN Case Study April 2014


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LEA/ - Effecti!e $ace 0tilisation

E))e$ti7e Da$e ;tilisation Gperatin Ti(e BGT

Calender Ti(e BCTH

ED;@ s te ratio o) operatin ti(e to $alendar ti(e reported as a per$entae

• t is used to (easure te e))e$ti7eness o) te &or' 9ein $arried out at te)a$e+

• t is NGT a Itry ardJ (easure

• To assist us to analyse te $y$le ti(e data &e use a(easure(ent 'no&n as ED;



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KME - Con!eyor Drift - E$0

40H -0H ED; 10 to 14 (p&

-0H 0H ED;

14 to 1= (p&

0H :0H ED; 1= to 24 (p&

• Tis rap de(onstrates te dire$t $orrelation 9et&een ED;and (eters ad7an$ed

Steady state

Coal sea(s, (ud, Me$ani$al issues

%est@32(p&



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Drifts Progress *ro!e*ent Plan

DRIFTS PROGRESS IMPROVEMENT PLAN

INITIATIVEDUE

DATERESPONSIBI

LITY STATUS as at 27/05/2010

Alterat!"e R#a$ %ea$er #rt!'#'s M!er e()AM105*MB+50

123&43%&2&

KME3'edat)'eort to +e reared +y Con Panidis and Katrina/o+es for re!ie5 $riday %6323%&2&

Sta$ar$!se Fa,e &'t-.ete,

123&43%&2&

'edat) "raining Package Being De!eloed

P!, $es!( # P!ea..le123&4%&2&

'edat)7ne cutting )ead )as +een returned to 7EMsecification8 5ill +e fitted on next )ead c)angeout day



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Drifts Progress *ro!e*ent Plan

I,rease &'tt!( P#err#- 200 t#300

123&93%&2&

'edat)/ot feasi+le8 *ajor structural and electrical

5ork re:uired t)at can not +e done att)e face;

Re"!e Ma!tea,ePra,t!,es

123&43%&

2&

'edat)

'oad (eader secialist engaged8*aintenance sc)edule de!eloed8re!ie5 of critical sares co*leted8re!ie5 *aintenance resources8 look at

%


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Drifts Progress *ro!e*ent PlanBert %#les ,l#se t# a,e

123&43%&2&

'edat) Suita+le drilling rig +eing sourced

Vert!,al Dra! #les !t#,#al sea-s

123&43

%&2&

KME

$easi+ility8 lanning and a!aila+ility

under5ay8 en!iron*ental aro!alsre:uired;

tr#l # O't6e ater123&43

%&2&

'edat)

=Drill rings of 9* relief )oles in 5et areas +elo5 t)e first coal sea*; >ill +e *arkedu and trial )oles to +e drilled o!er t)e 5eekend;=Key 5ay )as +een cut in t)e Con!eyorDrift 5)ic) 5ill allo5 us to install t)e

cattle grate su* as soon as t)e floor*o!es do5n to t)at osition; ")is 5illcontrol 5ater ost A:uila col sea*=Sua!ac ?u@@la u* is on site and 5ill +e co**issioned t)is 5eekend;=Auger to ena+le us to trial Bert )olesfor5ard of t)e floor is +eing sourced;=(essian sand +ags and sand )a!e +eendeli!ered to site8sa*e goes for < +y allets

of stonedust for da* +uilding;=9 +y ne5 rollcage dia)rag* u*s)a!e +een ordered due 53e


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KME – Project Concern Stris



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Progress *ro!e*ent

A$tual 7 Contra$t %aseline

Te &or( starts to turnLEAN (ple(ented

ee'ly tarets a$ie7ed

20( %eind

30 ( Cla&ed %a$'

"roress slu(p arrrested, (eetin &ee'ly tarets and pullin a 9it 9a$'KME, LEAN Case Study April 2014


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MB94& – Continuous Miner

M%-0 Continuous Miner arri7es on siteKME, LEAN Case Study April 2014


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LEA/ - Su**ary

• LEAN &ill not &or' &itout te $o((it(ent and dri7e )ro( LEANLeaders+

• LEAN in7ol7es te &ole &or')or$e+

• Iaste is easier to understand and re(o7e te $loser &e are to&ere it is $reatedJ+

• “Implementing Lean is simple but it aint easy”



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>)ats in it for Me

• A sa)e and produ$ti7e &or' pla$e &it #o9 satis)a$tion+• A 7alua9le e(ployee &it s'ills and a $ontinuous i(pro7e(ent (ind

set+• A syste( to i(pro7e produ$ti7ity as te )lo& on e))e$t o) i(pro7in

your 9onus+• "ro#e$t $o(pleted on ti(e and 9udet (eans your $o(pany

9e$o(es a $ontra$tor o) $oi$e )or te (inin industry+• our E(ployer $an’t do it &itout s'illed and $o((itted &or'ers+

Sa)e and appy &or'ers

Man, lo7etis ‘LEAN’

ope teydon’t 9rea'

anytintoday

Documents

Lean Case Study -Rio Tinto - Kestrel Coal Mine Extension Project - Rev 2014