Abstract

FOURIE, H.. Improvement in the overall efficiency of mining equipment: A case study. J. S. Afr. Inst. Min. Metall. [online]. 2016, vol.116, n.3, pp.275-281. ISSN 2411-9717.  http://dx.doi.org/10.17159/2411-9717/2016/v116n3a9.

In mechanized mining, poor equipment efficiency (availability, utilization, productivity, and quality) can endanger the success of the operation. This case study will show how an initiative to improve equipment performance developed into a comprehensive turnaround plan for the mine that placed it in the forefront of performance achievement. As part of a company-wide review process, poor overall equipment effectiveness (OEE) was identified as a major reason for the mine not achieving its targets. A project to improve the OEE identified eight improvement areas (elements) that contributed significantly to the poor performances. Measurement metrics were determined for these elements, followed by determination of baseline and target (improved) key performance indicators (KPIs). Cost savings associated with the improved efficiencies were calculated and tracked throughout the project. The mine team determined the specific actions required to achieve the target KPI in each element. These were individually developed and managed like mini-projects with allocated responsibilities for delivery The paper will indicate how this OEE improvement initiative triggered an improvement in almost all sections of the mine. Soon after launch, the initiative gathered momentum as the KPIs starting to improve. A visible tracking system exists at the mine and each employee can see the improvements and feel the success. The original eight elements were extended by five more, and the mini-projects grew as participants saw the success of the initiative. This paper concludes that through management and worker involvement, visible measurement and controls, and carefully chosen improvement elements, the mine was turned around. It is now achieving and exceeding its targets, and employee relations and motivation as well as safety have improved considerably. All of these achievements are reflected in the bottom line.

Keywords : overall equipment effectiveness; heavy mining equipment; productivity improvement; efficiency improvement; management support; cost reduction; motivated workforce; sustainability of success; key performance Indicators; action plans.

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