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ACARP Roadway Development Operator Workshop No 7. A Systems Approach to Roadway Development Mick Kelly, BMA Coal. Safety, Safety, Safety. A Systems Approach to Roadway Development. Components of Roadway Development Outline of “Systems Approach” Hierarchical Components - PowerPoint PPT Presentation
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ACARPACARPRoadway Development Roadway Development Operator Workshop No 7Operator Workshop No 7
A Systems Approach to Roadway DevelopmentA Systems Approach to Roadway Development
Mick Kelly, BMA CoalMick Kelly, BMA Coal
Safety, Safety, Safety
A Systems Approach to Roadway DevelopmentA Systems Approach to Roadway Development
Components of Roadway Development Outline of “Systems Approach” Hierarchical Components Focus on Process Improvement Importance of Information Flow
Process
Roof Support
Commu-
nication
MinerPumping
Panel Set-up
Shuttle
car
Standards
Hazard
Ma ps
CultureVentilation
Gas Control
KPI’s
Mining
Cr ew
BonusRoadway
Maintenance
Conveyor
Advance
Stone-dusting
Maintenance
Systems
Pro cessImprovement
Power
TrainingSafety
Roster
Firstly, a systems approach Firstly, a systems approach incorporates people issues and incorporates people issues and technology into processes – technology into processes – People are PivotalPeople are Pivotal
Systems Approach ?Systems Approach ?
Secondly, a systems approach must Secondly, a systems approach must understand the complexity of systems understand the complexity of systems structure and the dynamics of the structure and the dynamics of the interactions between processes.interactions between processes.
Systems ApproachSystems Approach
Thirdly, a systems approach recognises Thirdly, a systems approach recognises natural variability is a normal part of any natural variability is a normal part of any process.process.
Systems ApproachSystems Approach
Lastly, a systems approach recognises Lastly, a systems approach recognises that the collection and use of that the collection and use of information is a key factor.information is a key factor.
““Information is Data that Informs”Information is Data that Informs”
Systems ApproachSystems Approach
1. Mining Systems (cutting, bolting, transporting)
2. Organisational Factors (manning allocation and organisation, measurement systems and motivational factors)
3. Machinery Supply and Support
4. Strata Support and Gas Control
5. Systems Support (panel layouts, extensions, gas and water drainage, ventilation, floor control)
6. Maintenance Practice
7. The Human Element (workforce, management, culture, industrial environment)
8. Safety Systems
Key components and interactions of the Key components and interactions of the existing systemexisting system
Roadway Development Advance isdependent upon the combination of a seriesof processes. The critical path may vary intime and may not always be the miningsystem.
The first model is a simple form of process mapping (or a simple project management Gantt chart)
Roadway Development ModelsRoadway Development Models
The key questions to be answered are:
What is the process map at each level of the hierarchy?
What is the interaction between
hierarchies? Who is responsible for the overall
process at each hierarchical level? For each of these levels what is
measured and what is the focus?
Hierarchical ModelHierarchical Model
Whole ofMine
Panel
Pillar
Face
Mine Improvement Areas? Roster Design – Is the roster currently maximising
face, maintenance, set-up times? Formal Introduction of Process Improvement? Maintenance management system tailored to roadway
development requirements? Focus on data management for process improvement,
not historical data collection for upwards summaries. Bottom Line - STRONG FOCUS REQUIRED ON ENABLING
TEAM TO IMPROVE PROCESS KNOWLEDGE AND INCREASE THEIR ABILITY TO INFLUENCE
Panel Improvement Areas ? Separation of Panel with Mains – achieving that “push button
start” Use of project management approach in mains driveage
Panel Plan, Standard Area Methods Integration of activities Supply systems & wastage Hazard Plan, short interval control, feedback loops
Communication Plan Methods Reinforcement of Best Practice Formal feedback loops Hazard treatment, response time
Travel Time into face Total cost of driveage Design & Deliver Technology pack to allow cycle optimisation
Standard Area Methods
Aims: standardise the method of development across the
shifts establish “best” practice improve people’s knowledge of that practice formalise a process that will allow crews to initiate
improvement.
Pillar Cycle Improvement Areas?
Focus of Continuous Improvement into pillar cycle
Optimisation of panel extension– decoupling of non-critical tasks– teamwork interaction and training– “example” belt move– review after each pillar
Standards for longwall operation
Maintenance shift <> hot start both ways
Face Cycle Improvement Areas? THROW OUT SHIFT TARGETS
Understand constraints on uptime rates – empower team to remove
Understand constraints on utilisation time – empower team to remove
Reinforce cutting cycle optimisation
Reinforce panel standards
Reinforce alternative work options
Ensure effectiveness of maintenance delivery
Systems Approach
Emphasis on: Process improvement Use of Information
Natural VariationNatural Variation
Decreasing VariationDecreasing Variation
Reducing Variation of Sub-Reducing Variation of Sub-processesprocesses
Continuous ImprovementContinuous Improvement
Step ChangeStep Change
Information the Key
Remember information, not data is the key for success: Information should be analysed not averaged
• Setting effective KPIs is essential• Effective analyses for process improvement
Information should be 50% downward Feed back loops are a necessity for exception
reporting Use reviews to improve process knowledge
Site Commitment
The commitment from the mine will need to include: A desire to improve performance. Acceptance that this will involve a change process. Process must involve faceworker, middle
management as well as senior management support.
Process may involve a major change in the way information is collected and used.
Key to the Success Site commitment to Roadway Development
improvement to ensure it is fully integrated with all site activities
Some Takeaways Take the blinkers off with safety Holistic Approach – don’t just focus on face
equipment Define the process & give it an owner Use Process Improvement to attack waste Information to the process teams to drive
improved knowledge and empowerment Site commitment is essential
A systems approach incorporates people issues and A systems approach incorporates people issues and technology into processes – technology into processes – People are PivotalPeople are Pivotal