Determining the suitability of frontline production KPI's in managing production section downtime and identifying critical areas of lost time at Greenside Colliery

Abstract

Over recent years Anglo Coal Underground CM mines have consistently been able to increase production output by improving their production process efficiency. However, in the very same time, the utilization of available production time has declined. This report will explore the architecture of the current Performance Management System (PMS) for frontline production section in Greenside Colliery, with specials impetus given to the measurement front line time utilization. Guided by existing literature and case studies on Performance Measurement Systems and equipment time losses one was then able to conduct work studies in the erratic underground coal mining sections. This was done with the view of building a factual basis for process flows and root cause identification. Informed by the above the report will give recommendations, on the short comings and suitability of the current PMS, a concise definition of what ìproduction downtimeî and illuminate critical areas of lost production. From the study of best practices the PMS was found to be suited generally for frontline coal management. However more needs to be done in improving the accuracy of the data recorded and its communication. A definition was fabricated for Lost Production Time based on the existence of a critical value chain. Based on this definition the critical areas of lost production time were identified and summarized in diagrammatic form that will be used in the data capturing of the new PMS. The study found that Continuous Miner operational stoppages and Feeder Breaker breakdowns present the best opportunities of improvement and recommends that work studies be done to improve the operational stoppages and equipment redesign consideration be made to reduce shearing pin and torque shaft damage. The report culminates by giving further recommendations based on findings on other aspects that are not contained within the project scope but however do have a bearing on the efficiency of the total PMS.