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Kestrel Coal Mine Extension Project
KME, LEAN Case Study
A ‘LEAN’ Case Study
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KME Project – LocationSunny Australia
KME, LEAN Case Study
Emerald
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Background
• "ro#e$ted $ost 52+0 %illion
• Key Work Packages
6 T&in dri)ts, 1 ! Con7eyor, 1 ! Transport
6 Sin'in o) 8entilation Sa)t
6 Supply and install 8entilation )ans
6 "it 9otto( de&aterin prora(
6 "it 9otto( de7elop(ent o) (ine in)rastru$ture and lon&all panels
6 Constru$tion o) --0 (ea litre site storae da( and sedi(ent da(s
6 Constru$tion o) :'( $on7eyor to Kestrel
6 ;p rade o) C
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Drifts - Secifications
• Conveyor Drift
6 1-:: (etres lon at a radient o) 1@
6 Ar$ pro)ile +-( &ide ! 4+:-( i+
6 Con$rete se(ent )loor+
• Transport Drift
6 1=: (etres lon at a radient o) 1@=
6 Ar$ pro)ile +0( &ide ! 4+-( i+
6 Con$rete se(ent )loor+
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Con7eyor >ri)t@ nterse$ts $oal sea(s
Drifts - Con!eyor
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Drifts - "ransort
Transport >ri)t BSupport $lass 1
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Drifts - Construction
• Tere a7e 9een 4 (etods o) $onstru$tion to date in ea$ dri)t+• Method 1:
6 %o! $ut e!$a7ated ten stru$tural $on$rete ar$es and )loor
se(ents $onstru$ted and 9a$')illed+
• Method 2:
6
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Drifts – Cut # $ill
Con7eyor >ri)t 6 Metod 1 Cut Dill April 2014 KME, LEAN Case Study
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Drifts - Construction
• Method :
• eote$ni$al e7aluation ten deter(ined te lo$ation to
dis$ontinue te steel sets and s&it$ to rins o) 2+4( )ull $olu(n
resin ro$'9olts installed &it a Fu(9o and :-(( o) )i9re
rein)or$ed sot$rete+ BD?S
• E!$a7ation $ontinued &it te ydrauli$ e!$a7ator )itted &it a
.ui$' it$ to allo& te use o) te 9u$'et or a ro$' 9rea'er+
BSupport $lass 2
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Drifts – Steel Sets
>ri)t Constru$tion 6 Metod 2 Steel Sets April 2014 KME, LEAN Case Study
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Mitsui S%&& 'oad (eader - Attac)*ents
Sot$rete 9oo(
Sot$reteControlsBS&in out
%olter
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Case Study – KME Drift Construction
Con7eyor >ri)t 6 Cut &it Mitsui S200 ?oad
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'oad (eader
?oad
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'oad (eader – Sliding $loor
Con7eyor %oot End
Con7eyor sendsMaterial to Sur)a$e
%r i d ,e C o n7 e y o r
"re Cast Con$rete )loor se(entsSlidin Dloor
8 ent >u$ t B E ! aust C
Clean air
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Drifts – Concrete $loors
Con$rete )loor se(ents
>ri)t Cross Se$tion
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Drifts – Concrete $loors
"re$ast Con$rete )loor se(ent
Con$rete Ni9 6 "oured aead o)te slidin )loor
Sot$rete in)ill
Con$rete 9lindin
rout
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Drifts – Concrete $loors
"re$ast $on$rete )loorse(ents
+0( ! 1+3( !-+2 Tonne
"la$e(ent &it L
rout in#e$tion oles
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Drifts – Concrete $loors
Non slip e!posed areatesur)a$e
Se(ents in pla$e
Li)tin Lu
Ni9
%lindin Con$rete
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*ro!e*ent Cycle
KME, LEAN Case Study
et te )a$ts
"ro$ess Maps
nterroate >ataED; raps
>ri)ts(pro7e(ent
"lan
Con$ernStrips
Monitor
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nterrogate t)e Data
&tart .p
$amiliarisation
&teady &tate/Clay
M+dstones
$irst Coal &eam
Water/ m+d/ floor iss+es
&andstone
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.isualise t)e Cycle
"ro$ess Maps Con7eyor >ri)t Cy$le Ti(es
•Cy$le ti(es are 7ital to our oalo) $ontinuous i(pro7e(ent
•Ea$ ele(ent o) ea$ $y$le asa taret ti(e tat as 9eenareed 9y te tea( as realisti$and a$ie7a9le
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Cycle "i*e Process Ma
reen 6 ;nder Ti(e, ?ed 6 G7er Ti(eKME, LEAN Case Study April 2014
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LEA/ - Effecti!e $ace 0tilisation
E))e$ti7e Da$e ;tilisation Gperatin Ti(e BGT
Calender Ti(e BCTH
ED;@ s te ratio o) operatin ti(e to $alendar ti(e reported as a per$entae
• t is used to (easure te e))e$ti7eness o) te &or' 9ein $arried out at te)a$e+
• t is NGT a Itry ardJ (easure
• To assist us to analyse te $y$le ti(e data &e use a(easure(ent 'no&n as ED;
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KME - Con!eyor Drift - E$0
40H -0H ED; 10 to 14 (p&
-0H 0H ED;
14 to 1= (p&
0H :0H ED; 1= to 24 (p&
• Tis rap de(onstrates te dire$t $orrelation 9et&een ED;and (eters ad7an$ed
Steady state
Coal sea(s, (ud, Me$ani$al issues
%est@32(p&
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Drifts Progress *ro!e*ent Plan
DRIFTS PROGRESS IMPROVEMENT PLAN
INITIATIVEDUE
DATERESPONSIBI
LITY STATUS as at 27/05/2010
Alterat!"e R#a$ %ea$er #rt!'#'s M!er e()AM105*MB+50
123&43%&2&
KME3'edat)'eort to +e reared +y Con Panidis and Katrina/o+es for re!ie5 $riday %6323%&2&
Sta$ar$!se Fa,e &'t-.ete,
123&43%&2&
'edat) "raining Package Being De!eloed
P!, $es!( # P!ea..le123&4%&2&
'edat)7ne cutting )ead )as +een returned to 7EMsecification8 5ill +e fitted on next )ead c)angeout day
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Drifts Progress *ro!e*ent Plan
I,rease &'tt!( P#err#- 200 t#300
123&93%&2&
'edat)/ot feasi+le8 *ajor structural and electrical
5ork re:uired t)at can not +e done att)e face;
Re"!e Ma!tea,ePra,t!,es
123&43%&
2&
'edat)
'oad (eader secialist engaged8*aintenance sc)edule de!eloed8re!ie5 of critical sares co*leted8re!ie5 *aintenance resources8 look at
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Drifts Progress *ro!e*ent PlanBert %#les ,l#se t# a,e
123&43%&2&
'edat) Suita+le drilling rig +eing sourced
Vert!,al Dra! #les !t#,#al sea-s
123&43
%&2&
KME
$easi+ility8 lanning and a!aila+ility
under5ay8 en!iron*ental aro!alsre:uired;
tr#l # O't6e ater123&43
%&2&
'edat)
=Drill rings of 9* relief )oles in 5et areas +elo5 t)e first coal sea*; >ill +e *arkedu and trial )oles to +e drilled o!er t)e 5eekend;=Key 5ay )as +een cut in t)e Con!eyorDrift 5)ic) 5ill allo5 us to install t)e
cattle grate su* as soon as t)e floor*o!es do5n to t)at osition; ")is 5illcontrol 5ater ost A:uila col sea*=Sua!ac ?u@@la u* is on site and 5ill +e co**issioned t)is 5eekend;=Auger to ena+le us to trial Bert )olesfor5ard of t)e floor is +eing sourced;=(essian sand +ags and sand )a!e +eendeli!ered to site8sa*e goes for < +y allets
of stonedust for da* +uilding;=9 +y ne5 rollcage dia)rag* u*s)a!e +een ordered due 53e
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KME – Project Concern Stris
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Progress *ro!e*ent
A$tual 7 Contra$t %aseline
Te &or( starts to turnLEAN (ple(ented
ee'ly tarets a$ie7ed
20( %eind
30 ( Cla&ed %a$'
"roress slu(p arrrested, (eetin &ee'ly tarets and pullin a 9it 9a$'KME, LEAN Case Study April 2014
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MB94& – Continuous Miner
M%-0 Continuous Miner arri7es on siteKME, LEAN Case Study April 2014
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LEA/ - Su**ary
• LEAN &ill not &or' &itout te $o((it(ent and dri7e )ro( LEANLeaders+
• LEAN in7ol7es te &ole &or')or$e+
• Iaste is easier to understand and re(o7e te $loser &e are to&ere it is $reatedJ+
• “Implementing Lean is simple but it aint easy”
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>)ats in it for Me
• A sa)e and produ$ti7e &or' pla$e &it #o9 satis)a$tion+• A 7alua9le e(ployee &it s'ills and a $ontinuous i(pro7e(ent (ind
set+• A syste( to i(pro7e produ$ti7ity as te )lo& on e))e$t o) i(pro7in
your 9onus+• "ro#e$t $o(pleted on ti(e and 9udet (eans your $o(pany
9e$o(es a $ontra$tor o) $oi$e )or te (inin industry+• our E(ployer $an’t do it &itout s'illed and $o((itted &or'ers+
Sa)e and appy &or'ers
Man, lo7etis ‘LEAN’
ope teydon’t 9rea'
anytintoday