A PGM Mine in Limpopo Province, South Africa insourced the maintenance of their Sandvik Fleet of Trackless Mining Machines (TMM) consisting of Load Haul Dumpers (LHD), Dump Trucks (DT), Drill Rigs (DR) and Roof Bolters (RB). An in-house intranet-based planning and scheduling system were developed to record machine operational hours to schedule hour based services and do financial forecasting for major component replacements. Machine hours had to be captured manually in the workshops when machines were available which resulted is several challenges such as:
- No TMM Reporting were available.
- Poor data integrity as manual capturing of data was done irregular and filled with mistakes for various reasons.
- Machine movements and time spent at certain locations was unknown i.e. wash bays, diesel bays, workshops, workplaces etc.
- Engine idling hours versus machine transmission hours did not make sense at all.
- Major components without hour meters like axels, drifters and drive trains had to be measured to do accurate component replacement forecasting.
- Machine movements in the mine were unknown.
- Any operator can operate any machine which is in contradiction with Act 29 Clause 8.10(15).
The solution required the machine hour meters to be automated. A device must be installed on the machine and be hard-wired into the machine nervous system to record the required data. This had to be hard-wired as several machines are old and do not have the correct onboard digital hour collection equipment. A solution was scoped and Minelert Smartlink was selected for a proof of concept.
The solution components included:
- Minelert Machine Monitoring Unit (MMU) with WiFi.
- Minelert Operator Display Unit (ODU) with biometrics.
- Minelert Active tracking tags.
- Minelert TrackEYE Management Console and data controller.
- IT connectivity provided by the IT Department.
- Onsite installation and testing services.
Machines were identified and connectivity to the server room was established. Tracking tags were installed underground and on the surface. Machines were installed with the aid of the client workshop Foreman and auto electrician team.
Machine operational hours that were recorded included:
- Engine run time.
- Transmission run times.
- Transverter run times.
- Compressor run times.
- Powerpack run times.
- Percussion time and counts
Data put through to the in-house developed planning system was established and data started populating the planning system automatically on a daily basis.