SAIMM...The Thermal Coal Export Market Commodity Price Cycle External Cost Pressures, e.g. Power and Labour Lack of Investment and Capital Constraints The Productivity Improvement

SAIMM

Realising the Productivity Potential of Joy Continuous Miners in Underground South African Coal Mines

May 19th 2016

Dean Hoare

Mining Productivity Consultant.

19 May 2016 SAIMM - JoySmart Solutions All information presented is Confidential2

© 2015 Joy Global Inc. All rights reserved

Joy Global: Who We Are



Strategies: Creating Competitive Advantage

Consistent global world-class components, processes, methods,

and metrics throughout the global network with the ability to

rapidly customize locally

Safety ▪ Time ▪ Cost ▪ Quality ▪ Customer Satisfaction

World-Class COE’s

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Innovations Creating Growth China and High Growth Markets

LCM ▪ Consumables ▪ JoySmartSM Services Zero Harm ▪ Velocity ▪ Productivity ▪ Quality ▪ References

Lead with Service

$8B Market$2B Market

Hard Rock Mining Systems



Continuous Miner Cutting Cycle Simulations

(In development)

Room and Pillar Development

Continuous Miner Cutting



Continuous Miner Benchmarking performance South Africa

All Joy Continuous Miners are created equal – Yet many CMs under

perform against their design potential (why such variability)?

Joy Smart Solutions enables us to unlock the potential



The Magic Formula



Highest Production

Benchmarking Equipment and Operator

Performance and ‘closing the gaps’

Improving Time Management and Operating

Discipline

Reducing Downtime and Waste – Early Detection

and Improving Operating and Maintenance

Practices

Lowest Operating Costs

Increased Efficiency and LCM

Improving Safety

Key Deliverables from JoySmart Solutions

‘Making each Section Our Reference’



Continuous Miner – ‘Prime Mover and Bottleneck’

Continuous Miner Cutting Cycle – Tune-Up Optimisation

Cutter Amp Feedback Settings Control Sump Speed

Control Shear down rate

Conveyor Amp Feedback Settings Control Shear Down Rate

Variable Frequency Drive

Traction



Continuous Miner Cutting Cycle Profiles – Real Time Simulation Analysis



Example - Section Productivity - Key Performance Indicators

KPI Tracking of Core Mining Processes

-

50

100

150

200

250

-

50

100

150

200

250

300

350

400

450

500

Bas

e L

ine

Mo

nth

1

Mo

nth

2

Mo

nth

3

Mo

nth

4

Mo

nth

5

Mo

nth

6

Mo

nth

7

Mo

nth

8

Mo

nth

9

Mo

nth

10

Mo

nth

11

Mo

nth

12

Pro

du

ctio

n R

ate

To

nn

es/

Ho

ur

Pro

du

ctio

n T

ime

Min

ute

s

Production Time & Production Rate

Production Rate Production Time

5.00

6.00

7.00

8.00

9.00

10.00

11.00

12.00

13.00

Ton

ne

s /M

inu

te

Continuous Miner Cutting Rate

Cutting Rate

50

60

70

80

90

100

110

120

Seco

nd

s

Load and Away Time

Load Time Away Time

60%

65%

70%

75%

80%

85%

90%

Fill

Fact

or

%Shuttlecar Fill Factor

Fill Factor

-

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

Do

wn

tim

e H

ou

rs

CM Downtime

Down Time Hours

-

10

20

30

40

50

60

70

Min

ute

s

CM Relocation Time

Per Relocation Time mins



Example – CM Load Time Comparison:

Week 10

Week 31

As visible in the Boxplot comparison it is clear to see the focus with the Operator coaching’s from Mining

Specialist the improvement for all three shift Operators.

• A – Shift sustained the load quantity within 1% with an average load time of 70 seconds

• B – Shift decreased the load quantity by 25 % whilst decreasing load time from 75 to 64 seconds

• C – Shift increased the load quantity with 23% and decreased his average load time from 83 to 69 seconds



So What is in the JoySmart Solutions Tool Box

Visual Aide to repeating ‘Perfect Cutting Cycle’

A Production Timing Indication Light (PTIL) is a system for

continuous miners that will interact, through visual feedback, with

the shuttle car and CM operators.

It gives indications to the operators by using different signs:

When correct sump depth has been reached

When shuttle car should be full

When the next shuttle car should be behind the

miner

Thus creating cutting rhythm and consistent cycle tempo



Production Timing Indication Light (PTIL)

The production timing indication light (PTIL) provides a visual indication to the

operator, with regards to the time it takes to sump and load a shuttle car as well as

the shuttle car away time.

The PTIL will be set according to cutting conditions per section, thus settings will

differ from section to section.

The Production Timing Indication Light indicators are shown as Continuous Miners

and Shuttle Cars.

Smart Mining

On Board Display, improves

cutting cycle accuracy and

process tempo.



In-Section Audits; Productivity Analysis and Coaching

Section Layout and Set-Up

Section Layout/set-up Shuttle Cars Used Anchor Points Changeout Points Distance to Tip

Cable Lengths and

Management

3 In Order In orderLTR 2 Splits in front of

tip, 75m

CM cable not suspended in

LTR from R1 to L2

Cutting Sequence For 8 Road Section Splitting In R2

L4 L3 L2 L1 BR R 1 R 2 R 324 23 21 18 13 12 7 5

9 9

25 20 17 15 11 8 2 3

19 16 14 10 6 4 1

L4 L3 L2 L1 BR R1 R2 R3

F E D C

G A

B

SC 1229

SC1221 SC1222

Long Pillar

Belt

CM Cable SC/BH tram ruote Vent. IN Vent Out Scoop Brattice

Change out point Brattice CM cutting direction Anchor Points

Swit

ge

ѱ

ѱ

ѱ

ѱ

Embedded Mining Experts – Coaching and Best Practice Knowledge Transfer

An extract the

detailed section

evaluation report

Relentless

pursuit of the

BASICS



Joy Connect

All information and data contained on this document is the property of Joy Global and subject to the non disclosure agreements between Sasol Mining and Joy Global and may not be copied , distributed nor shown to any other party in any way, except with the prior written permission of Joy Global

Optimise Complete Value Stream

• Monitor the operating environment

• Additional sensors

• System Modelling and

Simulation

• Monitor operator effectiveness

• Mining sequence and routes

• Future section mapping (Wi-Fi)

• Manage out bye factors

• Bolting constraints

Live Operator

Display

Shuttle Car Load

Count – In field

Trials

Monitoring the full value stream - an integrated approach



Joy Connect : KPIs & Time Management JoySmart Solutions



Real Time Shift Report ‘Smartly Connected’

Real Time Visual Data – Empowering Short Term Decision Makers

..\Documents\Data\JoySmart Solutions\ShiftProgression.ppsx

../Documents/Data/JoySmart Solutions/ShiftProgression.ppsx



Cutting Cycle Analysis – Operator Interventions

Mining experts examined cutting cycle and developed method to

break up cutting cycle in order to compare operators/shifts

JoySmart

Re-playing CM Operator Practices – Coaching Tools to Best Practice

Example of a Miner Operator Cutting Profile



Cutting Cycle Analysis

MOVE SUMP SHEAR C/UP

22.25 s 20.12 s 28.18 s 4.55 s

TOTAL SHIFT CUTTING CYCLES:

AVERAGE CUTTING CYCLE TIME:PLUS EXTRA CLEAN UP TIME:

8338INCOMPLETE / NON CUTTING CYCLES:

70.55 s75.10 s

Fair Correlation to Consistent cutting cycle.

Dropping Head to

3.5m Alternate cutting

cycles, sump



AMC - Productivity Improvement Potential

Cutting Height

Cutting Amps

Conveyor Amps

Traction Amps

Cycle Time

Sump Time

Shear Time

Load Time

Trim Time

Cut Tons

Fill Factor

Cutting Rate

84

21

30

48

6

9

75%

6.4 t/min

78

25

30

42

6

10.8

90%

8 .3t/min

Base case Manual Operator Auto Cycle Profile

The Move to Zero Defects

Manual - Auto

Remote Operations – Systems Automation

A perfect cutting cycle; Replicated on command.



In Summary

Current Coal Mining Business Environment -

The Thermal Coal Export Market Commodity Price Cycle

External Cost Pressures, e.g. Power and Labour

Lack of Investment and Capital Constraints

The Productivity

Improvement

lever is potentially

fully within our

internal control.

When pulled it

can help position

us on the right

place on the cost

curve.

Example of Coal Cost Curve



In Summary



Any Questions?