Despite many regional differences, the primary challenges the mining industry faces are similar.

Mining software developer Modular Mining Systems believes the way in which these issues are dealt with, however, varies from company to company and can have a significant impact on profits if not properly dealt with.

The issues include the availability of skilled labour, lead times and the cost of acquiring capital equipment, the cost of maintaining equipment and near-record energy costs, says Modular Mining Systems VP Michael Lewis.

“These four challenges are [prevalent] in almost every mine around the world and are on executives’ minds daily. However, there are also other significant challenges that mines need to deal with that vary in degree from country to country. These issues include the safety issues in parts of Africa, for instance, which experiences high staff turnover and a lack of skilled workers. Many of these safety and operational challenges can be met with the correct application of technology, coupled with business process and change management,” he says.

All opencast mines have to deal with the challenge that large machines spend a significant amount of time on standby, or sitting idle while waiting for spare parts. The longer the equipment is not in active service, the lower the mine’s production capacity and, therefore, revenues will be.

Lewis suggests that fleet management software can assist in reducing idle time to a minimum, by continually monitoring production equipment and increasing the allocations of trucks to maximise production. “The Modular Dispatch system accomplishes this with a proven three-tiered optimisation algorithm,” he says.

“When it comes to maintenance, mines with reactive maintenance practices can experi- ence low physical availability of machines owing to high rates of catastrophic failures and time spent waiting for parts they were not planning to replace.

“Predictive maintenance systems, such as MineCare, monitor equipment degradation in real time, notifying analysts of problems in the early stages, so that more repairs can be done during planned maintenance stoppages, which result in lower maintenance costs, less downtime and fewer disruptions to production,” says Lewis.

Modular Mining’s experience shows that improving the haulage fleet has historically yielded production gains of between 5% and 34% and that implementation of predictive maintenance systems typically yield yearly direct maintenance savings for each truck of between $50 000 to $100 000.

Improving Software

Mines are like any other business and have to operate within a limited budget, which means they are all looking to cut costs wherever possible. Lewis believes some mines take capital rationing too far, sometimes delaying investments in significant technologies that can have an impact on direct operating costs.

But fleet management and maintenance management systems have demonstrated paybacks in a period of months rather than years by reducing operating costs and increasing productivity.

Further, the same production/cost processes are applicable in the area of safety. The arithmetic is simple: injuries reduce production and can cost significant amounts in payouts and legal fees, if the mine is found to be negligent. On the contrary, safe workers can deliver the goods and even improve production when safety and productivity are considered together.

“Fatigue often causes equipment operators to make mistakes, resulting in reduced productivity, equipment damage, and even injury. The Astrid fatigue management system continually monitors an operator’s fatigue level, alerting dispatchers or supervisors when a worker’s fatigue level exceeds the safe level. The fatigue level of every employee can be proactively managed by assigning them to interesting tasks, or to take breaks, that help keep their fatigue levels within the desired limits.

“Using additional technology such as proximity systems can have a similar effect. These systems not only protect operators, but eliminate the steep costs associated with equipment damage and production losses caused by accidents,” he says.

Skills Assistance

Lewis advises mines to embrace technology in developing its workers’ skills. New operators and even some experienced workers often do not follow cor- rect operating procedures. Operator abuses, such as speeding and excessive brake application in trucks can create serious safety concerns and even equipment damage, increasing maintenance costs and downtime.

Modular Mining’s Fast-Feedback module continually monitors operator performance and sends the operator a message whenever a specific condition is detected. For example, if an operator incorrectly uses the service brake, when he or she is supposed to use the retard pedal, a message is sent to the operator explaining the correct use. This immediate feedback, coupled with task training regard- ing the appropriate procedures, can be effective in improving operator performance, ultimately improving production and reducing maintenance costs.

“This does not always have to be a negative response. Best practice in this area involves encouragement of compliance with procedures through a scorecard system. Some mines create friendly competition, with the best performers being recognised monthly or quarterly,” explains Lewis.

However, not every challenge mines face can be overcome using technology, although many operations can be improved with the intelligent implementation of software solutions, designed to streamline and improve production, while limiting costly behaviours. This is not a simple process, but rewards are delivered in the form of continuous improvements in operations and productivity, without an increase in costs. The benefits contribute to the bottom line.