Large thermal coal mine in North America

Background

Background

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Producing more than 80 million tons of thermal coal a year this North American surface mine, located in the Powder River Basin, ranks amongst the largest coal mines in the world and operates a mixed fleet of draglines, electric and hydraulic shovels and wheel loaders.

This customer success story focuses on four P&H 4100 electric rope shovels that load a mixed fleet of haul trucks: Liebherr T282s (400 tons), Komatsu 960s (360 tons) and Komatsu 930s (320 tons).

The challenge

The challenge

The site was achieving less than 40% of their desired payload performance and was seeking to initially increase this to 70%

With payload performance falling below 40% of target, this mine site wanted to optimize their load and haul operations, and find a better way to improve operator performance, truck compliance and production, while reducing cost.

 

The solution

The solution

MineWare’s North American team worked with the mine to deploy the Argus Shovel Monitoring (Argus) system on their shovels, delivering an integrated system that provides real-time operator feedback, operator benchmarking, optimized payloads management tools.

To determine a baseline of current productivity the Argus systems were installed and commissioned. The Argus screen in the operator cab remained off while this data was collected over four weeks. This period was known as the Blind Study.

Argus operator training was subsequently rolled-out and the operator cab screens were powered on to provide real-time visuals to the operator.  The MineWare team continued to collect performance data for an additional four weeks. The data gathered allowed the mine site to understand what improvements resulted from the operators using the real-time feedback from the Argus system.

 

The results

Loading over 78,000 loads across the two four-week periods, the Argus systems increased the number of compliant trucks for all four P&H 4100 shovels. The results also highlighted that over one million additional tons of material had gone unrealized during the blind study.

35%
REDUCTION IN UNDERLOADS
From 54% to 19%
35%
INCREASE IN COMPLIANT TRUCKS
From 39% to 74%
1.2%
REDUCTION IN MAJOR OVERLOADS
From 1.6% to 0.4%
Payload Performance | Overall

Payload Performance | Overall

Argus enabled a 6.5% production increase.

Payload Performance | Per Shovel

Payload Performance | Per Shovel

Argus enabled consistent operator performance improvements, reducing operator variability across all four shovels.

Payload Distribution | Komatsu 960

Payload Distribution | Komatsu 960

The Komatsu 960 haul trucks had a 9.1% increase in payload compliance during the study.

The average payload compliance during the bind study was 93% and this increased to an average 101% with Argus turned on in the operator cab.

Payload Distribution | Komatsu 930

Payload Distribution | Komatsu 930

The Komatsu 930 haul trucks saw a 3.5% overall improvement in payload compliance.

The fleet had an average compliance of 98% during the first four weeks of the study which increased to 102% when Argus was turned on in the operator cab.

Payload Distribution | Liebherr T282

Payload Distribution | Liebherr T282

The Liebherr T282 haul trucks had a payload compliance improvement of 7.1%.

The fleet was averaging 92% which increased to 100% when Argus was turned on in the operator cab.

The outcome

The outcome

Shovel operator performance improved after four weeks of Argus on board, delivering impressive advantages in productivity and haul fleet efficiency.

The site increased their average truck loads per hour and moved more tons each day, resulting in a production increase equivalent to gaining two entire trucks.

If the site removed two of its existing trucks, they would maintain current production output while saving $3 million each year, based on current commodity pricing.

Shovel operator performance improved after four weeks with Argus, delivering impressive gains productivity and haul fleet efficiency.

Justin Johnson
Customer Value Manager, MineWare

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