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MANPOWER PLANNING OF AN IRON ORE MINES AND ORE PROCESSING PLANT– A CASE STUDY
PRESENTED BY: ANIRBAN DASGUPTA 2013MT0079 M.Tech (IEM) DMS, ISM DHANBAD
College Guide: Krishnendu Shaw Asst. Professor DMS, ISM Dhanbad
External Guide: D.S. Rekhi GM-IE&M HR&ES,JSPL Raigarh
Introduction
1DMS, ISM DHANBAD
Mining industry contributes 2 to 2.5% of total GDP of nation which is 10 to 11% of GDP of industrial sectors.
India possesses the 7th largest reserves of iron ore in the world
Demand of Ore increased
Production of Steel is increased
Manpower planning of Mines and Ore Processing Plant is essential
PROJECT GENESIS
Production need to increase proportionally with demand
of Iron Ore.
To support the required production, manpower
planning of Iron Ore Mines and Ore Processing Plant
(OPP) is required on urgent basis.
2DMS, ISM DHANBAD
Objective
To study and analyze the existing Manpower.
Propose the manpower requirement.
Optimize and make a model for manpower requirement .
3DMS, ISM DHANBAD
Literature Review
4DMS, ISM DHANBAD
Bowey (1977) defines:
Strategy for matching future manpower numbers and skills with organizational activities
Lagodimos and Leopoulos (2000) Proposed:
A mixed integer programming based model for the manpower shift-planning problem
L.H.C. Tippett(1935 ) Develops:
Work sampling (WS) technique, consists of a chain of random sampling (or observations) of the activities being carried out by the group of workers (or possibly the machines) under study
Case Study of Existing System
5DMS, ISM DHANBAD
Mining process and Production
• HEMM’s are used (e.g. Dozer, Shovel)
• Production of Mines 2.5 MTPA
Manpower
• In Mining 53 comp. and 47 contract employee
• In OPP 23 company and 60 contractual employee
Material Handling
• HEMM’s are used for material handling
Layout of OPPAF: Apron FeederDB: Down BeltSC: ScreenSD: Single DeckPC :Primary CrusherUB: Up BeltFB: Fines BeltCC: Cone CrusherDD: Double DeckRB: Recirculation BeltLC: Long ConveyorFEB: Feeder BeltJB: Junction BeltMP: Mini Plant
Ore Processing Plant Layout
Tipper Dumper
Feed Hopper
ROM (0-800mm)
AF
0-20mm (20MT/Hr) AF DB
0-25mm (250MT/Hr) SC 1 DB
SC 1 (SD)
Over Size
Primary Jaw Crusher (250TPH)
PC DB 0-100mm (100MT/Hr)
SC 2 (SD)
SC 2 DB
0-25mm (30MT/Hr)
SC 3 UB 0-25mm (250MT/Hr)
SC 3 (SD)
FB 3
0-3mm (300MT/Hr)
Fines Hopper
Tipper Dumper
CC UB Seconday
Cone Crusher
25-100mm (100MT/Hr)
CC DB 0-30mm
SC 5 (DD) SC 4 (DD)
LC 2
5-25mm (50MT/Hr)
Capacity 1500 MT Bin Hopper
FEB 5
FEB 4 0-6mm (50MT/Hr)
FB 1
0-6mm (50MT/Hr)
SC 3 DB 0-25mm (200MT/Hr)
0-20mm (150MT/Hr)
JB SC 6 (SD)
0-6mm (50MT/Hr) SC 6 DB
Fines Stock LC 3
0-20mm (130MT/Hr)
MP Hopper
MP Feed Belt
0-20mm (130MT/Hr)
MP SC
Recovery Belt (100MT/Hr)
Product (5-20mm)
Product (5-25mm)
Material Flow Belt/Conveyor
6DMS, ISM DHANBAD
Methodology
7DMS, ISM DHANBAD
Present Production level and related Production Equipment
Nature of Job (Work-content assessment using Work Sampling Technique)Volume based, Supervision based, Position based
Skill and Qualification Required
Statutory/Non-statutory Requirement
Technical/Non-Technical Requirement
Work sampling
Work sampling is defined as the application of statistical sampling techniques to the study of work activities. In the audit context, work sampling is typically used to estimate the proportion of workers' time that is devoted to different elements of work activity. Work sampling is also known as activity sampling. It can be also used to estimate equipment or vehicle utilization
DMS, ISM DHANBAD 8
Work sampling
DMS, ISM DHANBAD 9
Frequency of Study:
Samplings are made randomly or at fixed intervals.
Study Length:
Depends upon the job type. It is very important to make sure that equal numbers of sub-cycles are included in the study
Establish independent workload:
This will help insure that as many of the underlying variables which govern the work performed will be accounted for.
Working continuously without any break is not possible for any worker. Even under the best working method situation, the job will still demand the expenditure of the human effort and some allowance must therefore be made for recovery from fatigue and for relaxation. Allowances must also be made to enable the worker to attend to his personal needs.
Allowances
DMS, ISM DHANBAD 10
1. Rest and personal allowance: Drinking water, Taking rest
2. Process allowance: Waiting for work, Waiting for material
3. Contingency allowance: Waiting for the inspector, Consulting the supervisor
4. Special allowance: Calibration, Maintenance, Shut down
5. Policy allowance: According to the organizational policy
Types of Allowances
DMS, ISM DHANBAD 11
Standard Time & Normal Time
DMS, ISM DHANBAD 12
• Standard Time: Time required by an average skilled operator, working at a normal pace, to perform a specified task using a prescribed method
𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑡𝑖𝑚𝑒=𝑁𝑜𝑟𝑚𝑎𝑙𝑇𝑖𝑚𝑒+ 𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 .
• Normal Time: A standard performance time with 100% rating is considered as Normal Time to perform a job
𝑁𝑜𝑟𝑚𝑎𝑙𝑇𝑖𝑚𝑒=𝑂𝑏𝑠𝑒𝑟𝑣𝑒𝑑𝑇𝑖𝑚𝑒∗(𝑂𝑝𝑒𝑟𝑎𝑡𝑜𝑟 𝑅𝑎𝑡𝑖𝑛𝑔÷ 𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑𝑟𝑎𝑡𝑖𝑛𝑔)
Manpower Planning Process
13DMS, ISM DHANBAD
• Secondary data was collected from departments logbook, register etc.
Data Collection
14DMS, ISM DHANBAD
• Work Sampling technique is used for the field study of existing system.
Existing Deployment
DMS, ISM DHANBAD 15
Mines
Total Employees: 100
Company Employees: 45Contractual Employees: 55
Ore Processing Plant
Total Employees: 83
Company Employees: 23Contractual Employees: 60
Nature of job
DMS, ISM DHANBAD 16
Job
Volume Based
Position Based
Supervision Based
• Volume based manpower in Mines is Distributed in different HEMMs, their assessment is done depending upon the vehicle requirement in next section.
• Manpower (OPP): 5 Company, 27 Contractual• To determine Manpower required for different
activates in OPP following Mathematical formula is used:
Volume Base manpower
DMS, ISM DHANBAD 17
• Requirement of the position in overall operation is evaluated
• HEMM’s: 4 Shovels, 1 Drilling Machine, 8 Tippers, 1 Grader, 1 Dozer
• HMV’s and LMV’s: 1 water tank, 1 diesel tanker, 1 explosive van, 6 LMV and 2 Ambulance
• Manpower (Mines): 70
Position based manpower (Mines)
DMS, ISM DHANBAD 18
• Assessment of vehicle requirement is done by using following formula:
• To determine Manpower required for different activates in Mining following Mathematical formula is used:
• A excel model is prepared:Mining Model.xlsx
Vehicle Requirement Analysis
DMS, ISM DHANBAD 19
DMS, ISM DHANBAD 20
-1
1
3
5
7
9
11
13
15
17
19
21
23
25
27
8
4
1 1 1 1 1
5
3
1
25
16
3 2 2 2
67 7
Nos. of Vehicle Nos. of Manpower
Vehicle Vs. Manpower
Manpower assessment for Position Based JobDescription Measure
JE /Foreman 4 Nos.
Feed Hopper 3 Nos.
Primary Crusher, Screen-2, Down Belt 3 Nos.
Cone Crusher (Secondary Crusher) & SC-3 4 Nos.
Screen-4 & Screen-5 6 Nos.
Fines Hopper 4 Nos.
Bin Hopper 3 Nos.
MP Hopper, Screen-6 6 Nos.
Mobile Screen Plant 7 Nos.
EOT Crane Operator1 Nos.
DMS, ISM DHANBAD 21
Position based manpower (OPP)
• Position based manpower of OPP is decided on the basis of positions required for Operation. Following table show the different requirement.
• This type of manpower depends upon the number of area need to supervise or number of men need to supervise.
DMS, ISM DHANBAD 22
Supervision based manpower
Company (E) Contract (E) Company (P) Contract (P)0
5
10
15
20
25
30
35
40
45
37 3735
41
16
10
35
0
Manpower mapping based on Nature of Job for Mines
Positional ManpowerSupervision manpowerVolume based Manpower
DMS, ISM DHANBAD 23
Manpower (Mines)
Company (E) Contract (E) Company (P) Contract (P)0
5
10
15
20
25
30
35
12
33
12
29
6
0
5
0
5
27
1
21
Manpower assessment based on Nature of Job in OPP
Positional ManpowerSupervision manpowerVolume based Manpower
DMS, ISM DHANBAD 24
Manpower (OPP)
Manpower assessment based on Qualification of Mines
QualificationExisting Company Manpower Proposed Company Manpower
Company Contract Company Contract
B Tech 0 0 0 0
Diploma 0 0 0 0
Graduate 2 5 1 3
ITI 0 0 0 0
Skilled 31 19 30 23
Unskilled 0 0 0 0
Semi-Skilled 6 16 6 15
Foreman Certification 3 1 8 0
Mining Mate certification3 6 16 0
Ist Class Certificate 5 0 5 0
2nd Class Certificate 3 0 4 0
Total 53 47 70 41
DMS, ISM DHANBAD 25
Skill and Qualification Required
Manpower mapping based on Qualification of OPP
QualificationExisting Company Manpower Proposed Company Manpower
Company Contract Company Contract
B. Tech 1 0 1 0
Diploma9 0 8 0
Graduate0 1 0 1
ITI 8 33 7 31
Skilled2 11 2 9
Unskilled3 15 0 9
Total 23 60 18 50
DMS, ISM DHANBAD 26
Skill and Qualification Required
Manpower mapping based on Statutory Requirement of Mines
Statutory/ Non-Statutory
Existing Proposed
Company Contract Company Contract
Statutory 14 7 33 0
Non-Statutory 39 40 37 41
Total 53 47 70 41
DMS, ISM DHANBAD 27
Statutory/Non-statutory Requirement
Manpower mapping based on Statutory Requirement of OPP
Statutory/ Non-StatutoryExisting Proposed
Company Contract Company Contract
Statutory 0 0 0 0 Non-Statutory 23 60 18 50 Total 23 60 18 50
Manpower assessment based on Technical Requirement of Mines
Technical/ Non-technicalExisting Proposed
Company Contract Company Contract
Technical 15 7 34 0
Non-Technical 38 40 36 41
Total 53 47 70 41
DMS, ISM DHANBAD 28
Technical/Non-Technical Requirement
Manpower mapping based on Technical Requirement of OPP
Technical/ Non-technicalExisting Proposed
Company Contract Company Contract
Technical 20 46 18 40
Non-Technical 3 14 0 10
Total 23 60 18 50
• As per our assessment, there were total 4 extra men required including Mines and OPP. Result shown bellow.
DMS, ISM DHANBAD 29
Conclusion
Mining Manpower
OPP Manpower
Total manpower deployed
0 20 40 60 80 100 120 140 160 180 200
100
83
183
111
68
179
Proposed
Existing
Thank You