Load and Haul Fleet Selection

Based on Fixed Plant Production

 Load and Haul Fleet Selection
Based on Fixed Plant Production
Ways to Estimate Productivity !!
The typical view is machine centred …
 What are we going to do ?

• Review an approach which uses Crusher Output to

drive fleet selection.
• Use a simple spreadsheet to manage this process
e.g. no bunching or cycle mismatch included.
• Tie in the relevant concepts of earth and rock
moving into this process.
• Seek to reinforces the outlook that
You can’t Manage what you don’t Measure !
 Key Questions Addressed

What are the Production

Targets and Rates for Fixed Plant?
How much Time is Available?
What Primary Load & Haul
Production is required?
How much of an Hour does the
Loading Tool spend Loading?
What is the Load Area
Production Rate ?
What are the Cycle Times for
What is the Match of Loading Haulers and Loading Tool?
Tool and Haulers ?
What is the Key Characteristic
What does our Reality look like? of the Material?
Bunching and Cycle Mismatch
 Quarry Contacts
• Queensland and Northern Territory
• Paul Soden Hastings Deering, Brisbane
• New South Wales
• Andrew Black WesTrac, Sydney
• Victoria
• Ian Collins William Adams, Melbourne
• Tasmania
• Stuart Mc Donald William Adams, Launceston
• South Australia
• Mark Taylor Cavpower Adelaide
• Western Australia
• Steve Sakich WesTrac Perth
 Any Questions ?

The End
 Concepts
• Time Available
• Work Days per year
• Work Hours per Day
• Job Efficiency – Work Minutes per Work Hour
• Load Area Activities
• Material Density
• Load Factor and Fragmentation
• Fleet Match
• Cycle Times
• Bucket to Body Sizing – Effective Pass Ratios
• Bucket Fill Factor
 Concepts
• Time Available
• Work Days per year
• Work Hours per Day
• Job Efficiency – Work Minutes per Work Hour
• Load Area Activities
• Material Density
• Load Factor and Fragmentation
• Fleet Match
• Cycle Times
• Bucket to Body Sizing – Effective Pass Ratios
• Bucket Fill Factor
 Work Hours Available per Year
Availability & Utilization
An Example
Job Efficiency Factors Machine Availability Loss Utilization Loss Off Time Loss
Mismatch Unscheduled Downtime Ready, but unmanned Holidays
Bunching (90% On-Shift Availability) Shift Change Weather
Operator Efficiency Lunch & Meetings (4.1% Off Time)
(85% Job Efficiency) Scheduled Downtime &PM's
(87.5% Utilization)

PRODUCTIVE TIME 735 1050 360

6615 HRS HRS HRS HRS

Machine Operating Hours 4.1 %

(6615 HRS) 10 % 12.5% of
of of 8760
Machine Scheduled Hours 7350 8400
(7350 HRS)
Mine Scheduled Hours
(8400 HRS)
Total Annual Hours
(8760 HRS)
 Work Days per Year

• Full Days 220 days

• Partial Days 48 days
• Partial Day Factor 0.50
 Load & Haul Work Hours per Day
Load and Haul Scheduled Hours / Day 10 hours
less Non Operational Time
Mobilisation
Toolbox Talk - Inspect - Transit 20 minutes
Transit - Refuel - Shut Down 20 minutes
Breaks including Transit time
AM / PM Breaks 20 minutes
Lunch 45 minutes
Subtotal of Non Operational Time 1.75 hours
less Non Primary Load and Haul
Stock movement 0.75 hours
Overburden 0 hours
Subtotal Non-Primary Load and Haul 0.75 hours

Work Hours per Day 7.5 hours

 Job Efficiency /
Work Minutes per Work Hour
Job Efficiency is one of the most complex elements of estimating
production since it is influenced by factors such as operator skill,
minor repairs and adjustments, personal delays and delays
caused by job layout. An approximation of efficiency, if no job
data is available, is given below.
Efficiency
Operation Working Hour Factor
Day 50 minute hour 0.83
Night 45 minute hour 0.75

These factors do not account for delays due to weather or machine

downtime for maintenance and repairs.You must account for such
factors based on experience and local conditions.
What about time lost for watering the load area ?
 Analysis of Face Loader Activity

Load Area Activity of Wheel Loader

Non-Loading
Preparing to Load Activities
17 %
30 %

Predig Pile
8%
Maintain Floor
Loading Truck 2%
54 % Clean Floor
Remove Oversize 3%
17 %
 Concepts
• Time Available
• Work Days per year
• Work Hours per Day
• Job Efficiency – Work Minutes per Work Hour
• Load Area Activities
• Material Density
• Load Factor and Fragmentation
• Fleet Match
• Cycle Times
• Bucket to Body Sizing – Effective Pass Ratios
• Bucket Fill Factor
 Density of Materials
Material Bank Loose Load
kg/m 3 kg/m 3 Factor
Gravel - pit run 2179 1930 .89
Earth-dry 1900 1510 .80
Earth- wet 2020 1600 .79
Clay – natural bed2020 1660 .82
Topsoil 1370 950 .70
Shale 1660 1250 .75
Granite -broken 2730 1660 .61
Limestone 2610 1540 .59

Full Table in
PHB 42 P27-4
 Concepts
• Time Available
• Work Days per year
• Work Hours per Day
• Job Efficiency – Work Minutes per Work Hour
• Load Area Activities
• Material Density
• Load Factor and Fragmentation
• Fleet Match
• Cycle Times
• Bucket to Body Sizing – Effective Pass Ratios
• Bucket Fill Factor
 Machine Production
CYCLE TIME
Operator Skill

LOAD
Fixed Time
RETURN
Variable Time
Delays

HAUL DUMP
Variable Time Fixed Time
 Loading Tool / Hauler Pass Match

Target Truck Load Time

2 minutes

Target Exchange Time

0.7 minutes

Target Pass Match

Loader / Hauler = 3-5
Excavator / Hauler = 4-6
 Concepts
• Time Available
• Work Days per year
• Work Hours per Day
• Job Efficiency – Work Minutes per Work Hour
• Load Area Activities
• Material Density
• Load Factor and Fragmentation
• Fleet Match
• Cycle Times
• Bucket to Body Sizing – Effective Pass Ratios
• Bucket Fill Factor
 Bucket Fill Factor (BFF)

Material BFF as % of
Heaped Capacity
Moist Loam A- 100-120 %
Sand and Gravel Mix B- 95-110 %
Rock - Well Blasted C- 80 - 95 %
Rock - Poorly Blasted 50 - 75 %
12 –20mm Aggregate 85 - 90
A
BFF for Wheel Loader buckets tend to be
B
C 5 – 10 % higher than Excavator buckets due
to different angles of repose for SAE rating.

PHB 42
Pages 4-156, 9-161
 Quarry Contacts
• Queensland and Northern Territory
• Paul Soden Hastings Deering, Brisbane
• New South Wales
• Andrew Black WesTrac, Sydney
• Victoria
• Ian Collins William Adams, Melbourne
• Tasmania
• Stuart Mc Donald William Adams, Launceston
• South Australia
• Mark Taylor Cavpower Adelaide
• Western Australia
• Steve Sakich WesTrac Perth
 Any Questions ?

The End