Mine Production Hoist Optimization & Production OEE
A top tier global mining company, largely considered to be the biggest gold mining company in the world, had a major drive to increase its annual production performance from one of its key operating assets in Tanzania. The Tanzania based asset had struggled to achieve targets with the process plant constrained by supply of ore from the underground hoist.
The Tanzanian based mine site struggled to deliver the required amount of gold production due to low ore supply provided to the surface from the underground mine. The mine supplied ore to the surface with a generic mining hoist which was under performing. With limited measurement systems on the hoist and only manual data collected about the hoist performance, it was difficult to identify the losses required to be fixed, or what the actual capacity was of the hoist. The challenge presented was to discover the improvement opportunities required to increase production, and then increase production output from the hoist using the data to establish an improvement program while developing sustainability through local employees.
MPPIglobal launched an improvement initiative known as Production OEE. The solution incorporates sophisticated software that captures insight on production restrictions using a business improvement framework. The program incorporates a combination of integrated information technology and typical continuous improvement tools such as RCA and “5 Why’s.”
The project involved a brief period of discovery to establish existing systems, technology, integration requirements, reporting requirements, and solution design. A functional specification model was then assembled for the information technology deployment scope ready for execution. Change management and training requirements were then identified, and a plan developed to upskill the local work force in both technology use and business improvement processes. The project spanned 12 weeks from commencement of configuration to onsite commissioning of the technology used to drive improvements. Additional time was then used to support the improvement initiatives, provide training in technology use, and provide training in continuous improvement for local resources.
This deployment was implemented as part of a two-stage site program integrating with another Process Plant Production OEE model.
Increased data availability, visibility and production capacity in the hoist on average by 15% after a 4-month period. Main contributors were the collection of data loss, analysis and execution of improvement projects addressing issues of greater importance for increased production. Other results from these improvements include:
- Shorter hoist cycle times with less delays and stoppages.
- Shorter Load and dump cycle time through improved equipment reliability and operation.
- Consistently filled skips from all levels of the mine.
- Improved operator availability for surface load out to the ROM pad.
The project resulted in the hoist production capacity increasing by 15% over a 4-month period, removing the hoist as the constraint for the operation.