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Beltana DevelopmentBeltana Development
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Beltana OverviewBeltana Overview
Process Control Process Control
Continuous ImprovementContinuous Improvement
SummarySummary
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Beltana MG1 to 4Beltana MG1 to 4
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BeltanaBeltana
Located near Singleton.Located near Singleton.
Started in December 2001.Started in December 2001.
Set up as Individual Set up as Individual Business Units.Business Units.
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BeltanaBeltana
Total of Total of 2121 Million tonnes Million tonnes mined to date.mined to date.
Total of Total of 7070 km of roadway km of roadway driveage to date.driveage to date.
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Beltana DevelopmentBeltana Development
Drive 3.0m x 5.4m roadways.Drive 3.0m x 5.4m roadways.
Install 4 x 1.8m roof bolts with Install 4 x 1.8m roof bolts with mesh @ 1.5m spacings.mesh @ 1.5m spacings.
Install 2 x 1.2m rib bolts per 1.5m Install 2 x 1.2m rib bolts per 1.5m and once depth of cover exceeds and once depth of cover exceeds 175m 4 x 1.2m rib bolts per 1.5m.175m 4 x 1.2m rib bolts per 1.5m.
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Equipment UsedEquipment Used
Single Miner Unit with:Single Miner Unit with:
– 1 x 12cm12.1 x 12cm12.
– 2 x 10SC32 Shuttle cars 16 tonne 2 x 10SC32 Shuttle cars 16 tonne pay load.pay load.
– Stamler Breaker Feeder. (1700tph)Stamler Breaker Feeder. (1700tph)
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Process ControlProcess Control
Beltana is set up as 3 Business Beltana is set up as 3 Business Units that stand alone and are Units that stand alone and are aligned to a process.aligned to a process.
– Development Development
– LongwallLongwall
– ServicesServices
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Organizational ChartOrganizational Chart
Operations Manager
Longwall Coordinator
Development Coordinator
Production Coordinator
Development Engineer
Development Planner
Crew Supervisor
Maintenance Supervisor
Crew
Services
1010
DevelopmentDevelopmentLeadershipLeadership
Development Development EngineerEngineer
DevelopmentDevelopment
CoCo--ordinatorordinator
Development Development PlannerPlanner
Development Development ProcessProcess
Development Development EngineerEngineer
DevelopmentDevelopment
CoCo--ordinatorordinator
Development Development PlannerPlanner
Development Development ProcessProcess
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Process ControlProcess Control
Development team responsible for everything.Development team responsible for everything. ..– People People – Production / Maintenance StrategiesProduction / Maintenance Strategies– Materials / SparesMaterials / Spares– Process ImprovementProcess Improvement– Short term planShort term plan– CostsCosts– RebuildsRebuilds– BudgetsBudgets
The Process is not Operations and not The Process is not Operations and not Engineering it is Development.Engineering it is Development.
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Process ControlProcess Control
Crew Supervisors run their Crew Supervisors run their shift and are accountable to shift and are accountable to the Development Coordinator.the Development Coordinator.
Undermanager's do not fill a Undermanager's do not fill a traditional role.traditional role.
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Crew LeadershipCrew Leadership
Maintenance Maintenance SupervisorSupervisor
Crew Crew SupervisorSupervisor
Technicians & Technicians & TradesTrades
Development Development ProcessProcess
Maintenance Maintenance SupervisorSupervisor
Crew Crew SupervisorSupervisor
Technicians & Technicians & TradesTrades
Development Development ProcessProcess
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Process ControlProcess Control
Crew Supervisor’s have 12 men Crew Supervisor’s have 12 men in their crew.in their crew.
One being a Maintenance One being a Maintenance Supervisor.Supervisor.
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Process ControlProcess Control
Crew’s are responsible and Crew’s are responsible and accountable for everything accountable for everything inbye the portal.inbye the portal.
Contractors are used for roads Contractors are used for roads and stoppings only.and stoppings only.
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Beltana prides itself for Beltana prides itself for sustainability.sustainability.
If a key person is out of the system If a key person is out of the system then the process is sustainable.then the process is sustainable.
This is achieved by growing from This is achieved by growing from within.within.
Process ControlProcess Control
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This is both formal and informal but is This is both formal and informal but is looked at as a part of the culture.looked at as a part of the culture.
You can’t manage what you don’t You can’t manage what you don’t measure.measure.
This is achieved by planning involving This is achieved by planning involving the people, the people, implementing, implementing, measuring,measuring, reviewingreviewing and re-measure. and re-measure.
Continuous ImprovementContinuous Improvement
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Shift Start meetings.Shift Start meetings.
Shift reviews.Shift reviews.
Weekly Plan / Reviews.Weekly Plan / Reviews.
Continuous ImprovementContinuous Improvement
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Continuous Continuous ImprovementImprovement
Panel Panel Reviews.Reviews.
Supervisors meetings.Supervisors meetings.
Hazard / Improvement Process.Hazard / Improvement Process.
Panel Standards / Audits.Panel Standards / Audits.
2020
Continuous Continuous ImprovementImprovement
Beltana went from 4 to 7 Million Beltana went from 4 to 7 Million tonnes per year.tonnes per year.
Development had to develop a Development had to develop a process which could maintain a 7 process which could maintain a 7 million tonne Longwall.million tonne Longwall.
The following evolved.The following evolved.
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Continuous Continuous ImprovementImprovement
70/30m System Single Miner Unit 70/30m System Single Miner Unit (12CM30) 4m/hr system.(12CM30) 4m/hr system.
70m 30m
100m Cycle Metres Cut Rate Production
Section Advance Section Advance
Days Per Cycle m/hr Shifts Hours Shifts
7.2 250 3.9 11 21.7 2.9
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Continuous Continuous ImprovementImprovement
100m Pillar Single Miner Unit (1 x 100m Pillar Single Miner Unit (1 x 2CM30’s) 4m/hr system. 2CM30’s) 4m/hr system.
12% improvement12% improvement..100m Cycle Metres Cut Rate Production
Section Advance Section Advance
Days Per Cycle m/hr Shifts Hours Shifts
6.4 230 4 9.5 17.6 2.2
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Continuous Continuous ImprovementImprovement
100m Pillar Super Unit100m Pillar Super Unit(2 x 12CM30’s) 5.8 m/hr system.(2 x 12CM30’s) 5.8 m/hr system.
40% improvement40% improvement100m Cycle Metres Cut Rate Production
Section Advance Section Advance
Days Per Cycle m/hr Shifts Hours Shifts
4.6 236 5.7 8.2 25.7 3.2
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Continuous Continuous ImprovementImprovement
100m Pillar Single Miner Unit100m Pillar Single Miner Unit(1 x 12CM12) 6.5m/hr system.(1 x 12CM12) 6.5m/hr system.
24 % improvement.24 % improvement.
Total Process Improvement 95%Total Process Improvement 95%100m Cycle Metres Cut Rate Production
Section Advance Section Advance
Days Per Cycle m/hr Shifts Hours Shifts
3.7 236 5.5 7.6 18.5 2.3
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Continuous Continuous ImprovementImprovement
People and the machines are the success to our process.
Due to the fact that people were involved, they selected and then owned the machines and the process.
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Continuous Continuous ImprovementImprovement
Ergonomics was a major Ergonomics was a major consideration in our machine consideration in our machine selection process.selection process.
The following slides show the final The following slides show the final result.result.
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12CM1212CM12
2828
ErgonomicsErgonomics
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10SC3210SC32
3030
Stamler Breaker FeederStamler Breaker Feeder
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Stamler Breaker FeederStamler Breaker Feeder
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SummarySummary
Our People are our No.1. Our People are our No.1. asset.asset.
We Control the whole Process.We Control the whole Process.
We are committed to detailed We are committed to detailed Planning.Planning.
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SummarySummary
The Process is owned by all The Process is owned by all stakeholders.stakeholders.
We strive for very high Standards. We strive for very high Standards.
High = Safe + High = Safe + ProductiveProductiveStandards PlaceStandards Place Place Place
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Beltana Single Beltana Single
Miner UnitMiner Unit
Maintenance
Pipe Extension
Retics / DCB
Section Advance
0