3/6/2018 Pit, Haul Fleet, and Crushing Optimization Tony Gianni Trimble LOADRITE Presenter Introduction • Eastern NA Sales Manager Trimble Loadrite • 5 years as Technical Support Engineer • Hundreds of quarries around the world • Belt scales, plant integration, online reporting 1
3/6/2018 Transforming The Way The World Works Overview Unique Position • • Company founded in 1978 Rich domain knowledge • • Publicly traded on the NASDAQ Field-centric since 1990 • Solutions focused • 2014 Revenue $2.5B; 8,000+ • Mixed fleet support employees • OEM partnerships • Customers in 150+ countries • Global reach • Transforming industrial work • Local support processes through integrated positioning, communications and information technologies • Over 2,000 patents issued Transforming The Aggregates Workflow EXTRACTION PROCESSING LOADOUT PRODUCTION TRANSPORT CONSTR SITE ● Reduce transactional friction ● Optimize overall equipment utilization ● Reduce waste at hand-off points ● Reduce cost of production/transport ● Improve information accuracy ● Reduce waste and errors ● Improve information completeness ● Improve customer service and prices ● Protect the integrity of the ● Improve community relations information ● Improve safety ● Provide transparency to all participants Agenda • Define “Connected Quarry” – Available Technology • Performance Metrics and Operational Improvements • Common causes of increased costs, reduced efficiencies • Effect on productivity and production • Equipment, technology to correct issues • Expected potential savings with process improvement through sample quarry • Customer examples 2
3/6/2018 THE CONNECTED QUARRY The Connected Quarry • Real time link/visibility of all three zones o Extraction o Processing o Loadout • Staying connected to operations • Connecting people to the process Available Technology EXTRACTION PROCESSING LOADOUT Information Management & Reporting • Pit loading scales • Loader scales • Conveyor Belt Scales • Haul Truck Monitoring • Loadout integration • Downtime Entry • Drill positioning • • Conveyor Belt Scales Plant Automation • Dredge positioning 3
3/6/2018 Available Technology • Cloud based reporting – Fix Today’s Problems – Increased Accessibility – Operational Analysis KEY PERFORMANCE INDICATORS Key Performance Indicators • Meeting production hours • Sales • Equipment utilization • Production cost • Inventory • Production / target • Utilization vs scheduled time • Cost / ton • Inventory / sales ratio 4
3/6/2018 Agenda • Throughput per hour • Cost per hour • Idling, running empty • Reduction of wasted material • Value of service SAMPLE QUARRY Sample Quarry Operation • Production: o 900,000 ton theoretical capacity o Selling 730,000 tons per year, at $10/ton • Fleet: o Pit: 1 Drill (1 shot/ 2 wks), 1 Pit Loader, 3 Haul Trucks o Processing: 3 crushers, 10 belts o Loadout: 4 Loaders, 1 water truck, 1 weigh bridge • Other parameters: o 17 staff o 11 months/yr, 5 days/wk, 8 hrs/day operation 5
3/6/2018 Sample Quarry Operational Metrics Sample Quarry Income Statement 6
3/6/2018 EXTRACTION Extraction • Load correctly from the pit loader • Eliminate guesswork involved in haul truck loading • Manage blast performance • Quickly identify opportunities for improvement in loading, cycle times, equipment utilization and maintenance Extraction 7
3/6/2018 Extraction • Pit loader scales optimize the load in each truck – By loading closer to optimal weight, avoid under loaded trucks, and reduce the number of cycles – Optimize truck loads and cycle times, minimize fuel consumption and maintenance costs Extraction • Not all operators are the same • Load out management system helps to: – Identify ‘A’ operators – Assist ‘B’ and ‘C’ operators Extraction • Haul trucks activity – Loading time – Haul time – Queuing time • Shows machinery availability/performance – Identifies bottlenecks, bunching/line-ups – Empowers fleet managers to make improvements that affect production during the shift 8
3/6/2018 Extraction • Automated product totals provides accurate production figures • Avoid tabulating load sheets • Highlights material movement issues • Increased Safety Extraction Extraction #34 hauls 2 t more every time. Is it better? #34 takes 2 min more every cycle #34 does 10 t/h less. Less productive! Why did #34 starts late and finishes early?? Is the Pit keeping up with the • primary crusher? Key metric is ton per hour – More truck loads, not necessary more ton – More ton/truck, not necessary more productive • With measures, you can manage machines, processes & people *A quarry in North Carolina. LOADRITE loader scale installed on a pit-loader 9
3/6/2018 Extraction Shap Beck Quarry “ Having Loadrite systems and reports was like putting reading glasses on. We • X2350 Excavator Scale could see and analyze every detail of our • Reporting software operation.” - Chris Herbert, plant supervisor Shap Eighty (80) day Payback Beck Quarry, UK • Purely from optimizing haulage Additional value from: • Better management of blasting contractors • Hard data to right-size equipment Recommended to rollout on largest global sites Extraction • Higher Efficiency – Reduce truck cycle time • Higher Productivity – Reduce the number of truck cycles • Monitor blast efficiency • Reduce re-handling Extraction • 2 more trucks • 1 minute reduction in cycle time • Cost improved by 10 cents/ton ($100,000 decrease) • With a system that costs about 2.2 cents/ton (over 7 years) 10
3/6/2018 EXTRACTION – EXAMPLE Extraction – Example Surge Hopper Primary 3042 Lippmann Bin 44 SBS 6x16 Screen Telsmith 48 1 Telsmith 4in, 1¾, 11/2 3/4 6x16 1 ¾ + Wash 1 5x14 Screen 5x16 Screen 1/2 3/8 Deck Deck Plant 52 Telsmith ½ Wash 3/8 Wash Bin Bin Wash Extraction – Example • What was the issue? – Large amount of material returned – Gradation showed 90% correctly crushed – First screen off primary major bottleneck – Plant slow down to 175TPH – 10 years in place 11
3/6/2018 Extraction – Example Primary Crusher 350.00 300.00 250.00 200.00 150.00 100.00 50.00 0.00 6 AM 8 AM 11 AM 1 PM 3 PM 8 AM 10 AM 12 PM 2 PM 12 PM 2 PM 8 AM 10 AM 12 PM 8 AM 10 AM 12 PM 2 PM 6 AM 8 AM 10 AM 12 PM 2 PM 7 AM 9 AM 11 AM 1 PM 3 PM 9 AM 11 AM 1 PM 3 PM 11 AM 1 PM 3 PM 8 AM 10 AM 12 PM 2 PM 4 PM 10-Sep 11-Sep 15- 16-Sep 17-Sep 18-Sep 21-Sep 22-Sep 23-Sep 24-Sep Sep Extraction – Example • Theoretical: – Cycle time: 5 – 6 minutes = 10 Pit cycles per hour – Load Weight: 30 ton – 10 cycles x 30 tons = 300 tons Plant per hour Loadout Extraction – Example Truck Load Weight 100 80 60 40 20 0 28-28.5 28.5-29 29-29.5 29.5-30 30-30.5 30.5-31 31-31.5 31.5-32 32-32.5 32.5-33 33-33.5 33.5-34 34-34.5 34.5-35 35-35.5 35.5-36 36-36.5 36.5-37 37-37.5 12
3/6/2018 Extraction – Example Truck Cycle Time 600 Count of Cycles 400 200 0 0:04 0:05 0:06 0:07 0:08 0:09 0:10 0:11 0:12 0:13 0:14 0:15 Cycle Time in Minutes Extraction – Example Hauling Tons Per Hour 400.00 300.00 200.00 100.00 0.00 6 10 1 8 11 12 7 10 8 11 2 8 11 2 9 12 3 11 2 11 2 8 11 2 8 11 2 AM AM PM AM AM PM AM AM AM AM PM AM AM PM AM PM PM AM PM AM PM AM AM PM AM AM PM 10-Sep 11-Sep 15- 16-Sep 17-Sep 18-Sep 21-Sep 22-Sep 23-Sep 24-Sep 25-Sep Sep Extraction – Example 400.00 350.00 300.00 250.00 200.00 150.00 100.00 50.00 0.00 6 AM 8 AM 11 AM 1 PM 3 PM 8 AM 10 AM 12 PM 2 PM 12 PM 2 PM 8 AM 10 AM 12 PM 8 AM 10 AM 12 PM 2 PM 6 AM 8 AM 10 AM 12 PM 2 PM 7 AM 9 AM 11 AM 1 PM 3 PM 9 AM 11 AM 1 PM 3 PM 11 AM 1 PM 3 PM 8 AM 10 AM 12 PM 2 PM 4 PM 10-Sep 11-Sep 15- 16-Sep 17-Sep 18-Sep 21-Sep 22-Sep 23-Sep 24-Sep Sep Primary Crusher Face to Haul 13
3/6/2018 PROCESSING Processing • Increase the profitability of operations by monitoring and improving your crushing and screening • Measure production, energy from crushers and screens • Monitor throughput on conveyor belts to calculate stockpile tonnage Processing • Installation of belt scales to monitor flow of product through the system • Visibility into plant operations • Process Management – Over/under loading – Stop time – Black belt time 14
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