ACARPACARPRoadway Development Roadway Development Operator Workshop No 7Operator Workshop No 7

A Systems Approach to Roadway DevelopmentA Systems Approach to Roadway Development

Mick Kelly, BMA CoalMick Kelly, BMA Coal

Safety, Safety, Safety

A Systems Approach to Roadway DevelopmentA Systems Approach to Roadway Development

Components of Roadway Development

Outline of “Systems Approach”

Hierarchical Components

Focus on Process Improvement

Importance of Information Flow

Process

Roof Support

Commu-

nication

Miner

Pumping

Panel Set-up

Shuttle

car

Standards

Hazard

Ma ps

CultureVentilation

Gas Control

KPI’s

Mining

Cr ew

BonusRoadway

Maintenance

Conveyor

Advance

Stone-dusting

Maintenance

Systems

Pro cessImprovement

Power

TrainingSafety

Roster

Firstly, a systems approach Firstly, a systems approach incorporates people issues and incorporates people issues and technology into processes – technology into processes – People are PivotalPeople are Pivotal

Firstly, a systems approach Firstly, a systems approach incorporates people issues and incorporates people issues and technology into processes – technology into processes – People are PivotalPeople are Pivotal

Systems Approach ?Systems Approach ?

Secondly, a systems approach must Secondly, a systems approach must understand the complexity of systems understand the complexity of systems structure and the dynamics of the structure and the dynamics of the interactions between processes.interactions between processes.

Secondly, a systems approach must Secondly, a systems approach must understand the complexity of systems understand the complexity of systems structure and the dynamics of the structure and the dynamics of the interactions between processes.interactions between processes.

Systems ApproachSystems Approach

Thirdly, a systems approach recognises Thirdly, a systems approach recognises natural variability is a normal part of any natural variability is a normal part of any process.process.

Thirdly, a systems approach recognises Thirdly, a systems approach recognises natural variability is a normal part of any natural variability is a normal part of any process.process.

Systems ApproachSystems Approach

Lastly, a systems approach recognises Lastly, a systems approach recognises that the collection and use of that the collection and use of information is a key factor.information is a key factor.

““Information is Data that Informs”Information is Data that Informs”

Lastly, a systems approach recognises Lastly, a systems approach recognises that the collection and use of that the collection and use of information is a key factor.information is a key factor.

““Information is Data that Informs”Information is Data that Informs”

Systems ApproachSystems Approach

1. Mining Systems (cutting, bolting, transporting)

2. Organisational Factors (manning allocation and organisation, measurement systems and motivational factors)

3. Machinery Supply and Support

4. Strata Support and Gas Control

5. Systems Support (panel layouts, extensions, gas and water drainage, ventilation, floor control)

6. Maintenance Practice

7. The Human Element (workforce, management, culture, industrial environment)

8. Safety Systems

Key components and interactions of the Key components and interactions of the existing systemexisting system

Roadway Development Advance isdependent upon the combination of a seriesof processes. The critical path may vary intime and may not always be the miningsystem.

The first model is a simple form of process mapping (or a simple project management Gantt chart)

Roadway Development ModelsRoadway Development Models

The key questions to be answered are:

What is the process map at each level of the hierarchy?

What is the interaction between

hierarchies? Who is responsible for the overall

process at each hierarchical level? For each of these levels what is

measured and what is the focus?

Hierarchical ModelHierarchical Model

Whole ofMine

Panel

Pillar

Face

Mine Improvement Areas? Roster Design – Is the roster currently maximising

face, maintenance, set-up times?

Formal Introduction of Process Improvement?

Maintenance management system tailored to roadway development requirements?

Focus on data management for process improvement, not historical data collection for upwards summaries.

Bottom Line - STRONG FOCUS REQUIRED ON ENABLING TEAM TO IMPROVE PROCESS KNOWLEDGE AND INCREASE THEIR ABILITY TO INFLUENCE

Panel Improvement Areas ? Separation of Panel with Mains – achieving that “push button

start” Use of project management approach in mains driveage

Panel Plan, Standard Area Methods Integration of activities Supply systems & wastage Hazard Plan, short interval control, feedback loops

Communication Plan Methods Reinforcement of Best Practice Formal feedback loops Hazard treatment, response time

Travel Time into face Total cost of driveage Design & Deliver Technology pack to allow cycle optimisation

Standard Area Methods

Aims: standardise the method of development across the

shifts establish “best” practice improve people’s knowledge of that practice formalise a process that will allow crews to initiate

improvement.

Pillar Cycle Improvement Areas?

Focus of Continuous Improvement into pillar cycle

Optimisation of panel extension– decoupling of non-critical tasks– teamwork interaction and training– “example” belt move– review after each pillar

Standards for longwall operation

Maintenance shift <> hot start both ways

Face Cycle Improvement Areas?

THROW OUT SHIFT TARGETS

Understand constraints on uptime rates – empower team to remove

Understand constraints on utilisation time – empower team to remove

Reinforce cutting cycle optimisation

Reinforce panel standards

Reinforce alternative work options

Ensure effectiveness of maintenance delivery

Systems Approach

Emphasis on: Process improvement Use of Information

Natural VariationNatural Variation

Decreasing VariationDecreasing Variation

Reducing Variation of Sub-Reducing Variation of Sub-processesprocesses

Continuous ImprovementContinuous Improvement

Step ChangeStep Change

Information the Key

Remember information, not data is the key for success: Information should be analysed not averaged

• Setting effective KPIs is essential• Effective analyses for process improvement

Information should be 50% downward Feed back loops are a necessity for exception

reporting Use reviews to improve process knowledge

Site Commitment

The commitment from the mine will need to include: A desire to improve performance. Acceptance that this will involve a change process. Process must involve faceworker, middle

management as well as senior management support.

Process may involve a major change in the way information is collected and used.

Key to the Success Site commitment to Roadway Development

improvement to ensure it is fully integrated with all site activities

Some Takeaways

Take the blinkers off with safety Holistic Approach – don’t just focus on face

equipment Define the process & give it an owner Use Process Improvement to attack waste Information to the process teams to drive

improved knowledge and empowerment Site commitment is essential

A systems approach incorporates people issues and A systems approach incorporates people issues and technology into processes – technology into processes – People are PivotalPeople are Pivotal