ESTIMATING PRODUCTION

BY UNIT CAPACITY

Small Class Training Presented by :

- Alfirmansyah
22th January 2010
- Heris Aditya
 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

Production = n x Unit Production x UA x PA x Scheduled Time

n = Number of Unit
Unit Production = Volume moved per hour (BCM/Hr)
UA = Utilization Availability (%)
PA = Physical Availability (%)
Scheduled Time = Number of hour scheduled (Hrs)

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UNIT I ON
UCT
D
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 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

UNIT PRODUCTION (P)

Unit Loader (Excavator)

P = Bucket Vol. x Fill factor x 3600 x Efficiency

Cycle Time

Bucket Vol. = Bucket volume [CuM]

Fill factor = Bucket filling factor (related with excavating condition) [%]
3600 = number of second in one hour
Efficiency = Working efficiency (related with working condition and operator
skill) [%]
Cycle time = number of time used for a complete work phase
(digging – loading - digging) [sec]

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 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

UNIT PRODUCTION (P)

Unit Loader (Excavator)

Fill Factor
Condition Remark Bucket fill factor
Easy Excavating natural ground of clayey soil, clay, or soft soil 1.1 ~ 1.2
Average Excavating natural ground of soil such as sandy soil and dry soil 1.0 ~ 1.1
Rather difficult Excavating natural ground of sandy soil with gravel 0.8 ~ 0.9
Difficult Loading blasted rock 0.7 ~ 0.8

Cycle Time

CYCLE TIME TABLE (SECOND)

SWING ANGLE
TYPE
450 - 900 900 - 1800
PC 200 13 - 16 16 - 19 900

PC 300 15 - 18 18 - 21
PC 400 16 - 19 19 - 22 1800

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 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

UNIT PRODUCTION (P)

Unit Hauler (Truck)

P = Vessel Vol. x 60 x Correction factor

Cycle Time

Vessel Vol. = Vessel volume [CuM]

Correction = related with working condition, operator skill, material type, etc
[%]
Cycle time = number of time used for a complete work phase [mins]
60 = number of minute in one hour

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 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

UNIT PRODUCTION (P)

Unit Hauler (Truck)

Cycle Time
Hauling
Time

Loading Dumping
Time Time

Spot & Returnin

Delay Time g Time

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 ILI TY
I LA B
AVA
 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

AVAILABILITY

MA = Machine Availability

MA = (Work Time)
(Work Time + Repair)

Factors that show availability for doing activities by determining lost time
because mechanical reason.

PA = Physical Availability

PA = (Work Time + Standby Time)

(Time Scheduled)

Factors that show availability for doing activities by determining lost time
because several factor beside mechanical reason.

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 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

AVAILABILITY

UA = Use of Availability

UA = (Work Time)
(Work Time + Standby Time)

Factors that show rate of time utilized by machines for operating in its time
utilization.

EU = Effective Utilization

EU = (Work Time)
(Time Scheduled)

Factors that show rate of time utilized by machines for operating in its
entire time utilization.

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 S IN G ON
U CTI
D U
PRO E
A BL
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 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

PRODUCTION TABLE - TIME

W1 W2 W3 W4 W5
PLAN TARGET AS WEEKLY TOTAL
1 -7 8 - 14 15 - 21 22 - 28 29-31
Total of days 7 7 7 7 3 31
Holiday 0 0 0 0 0 0
Available days 7 7 7 7 3 31

LOCATION OVER BURDEN

PC 400 2 2 2 2 2
W1 W2 W3 W4 W5
WORKING HOURS Hy SL 450 1 1 - - TOTAL
- Assump.
1 -7 8 - 14 15 - 21 22 - 28 29-31
Rest & Meal OB (BCM) 14 47.643 14 47.643
14 32.300
14 32.300
6 13.260
62 173.145
2,0
Friday PrayingCOAL WINNING 2 2 2 2 2 10 2,0
Rain & Slippery 28 28 28 28 12 124 4,0
PC 300 1 1 1 1 1
Front Preparing 7 7 7 7 3 31 1,0
COAL (TON) 10.498 10.498 10.498 10.498 4.310 46.300
Shift change 14 14 14 14 6 62 2,0
Safety Talk OVER BURDEN 1 1 1 1 1 5 1,0
Other PC 400 7 7 7 77 7 7 3 7 317 1,0
Total Loss Time 73 73 73 73 33 325
SL DAEWOO 2 2 2 2 2
Available Days 7 7 7 7 3 31
Available Hour Hy SL 450 24 1 24 1
24 24 2 24 2 2
120 24,0
Time Scheduled OB (BCM) 168 143.735 168 143.735
168 143.735
168 143.735
72 59.007
744 633.947
Effective working hours 95 95 95 95 39 419
COAL WINNING
CAT 330 DL 1 1 1 1 1
PC 200 (coal) 0,5 0,5 0,5 0,5 0,5 12 /16
COAL (TON) 13.728 13.728 13.728 13.728 5.636 60.546
 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

PRODUCTION TABLE - PRODUCTIVITY

PLAN PA, UA AND PRODUCTIVITY W1 W2 W3 W4 W5

UNIT %PA %UA %UA %UA %UA %UA

PC 400 85% 49% 49% 49% 49% 46%

Hy SL 450 85% 49% 49% 49% 49% 46%
SL DAEWOO 85% 49% 49% 49% 49% 46%
PC 300 85% 49% 49% 49% 49% 46%
PC 200 85% 49% 49% 49% 49% 46%
Effective Working Hours/Day 14 Hours/Day

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 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010
W1 W2 W3 W4 W5
PRODUCTION TABLE - ALLOCATION
1 - 7 FLEET 8 - 14 15 - 21 22 - 28 29-31
7 7 7 7 3 31
0 0 0 0 0 0
W1 W2 W3 W4 W5
7 7 7 7 3 TOTAL
31
1 -7 8 - 14 15 - 21 22 - 28 29-31
LOCATION OVER BURDEN 7 7 7 7 3 31
PC 400 0 2 0 2 0 2 0 2 0 2 0
Hy SL 450 7 1 7 1 7 - 7 - 3 - 31
OB (BCM) 47.643 47.643 32.300 32.300 13.260 173.145
P7000 Bk07
LOCATION OVER BURDEN
COAL WINNING
PC 400 2 2 2 2 2
PCSL300
Hy 450 1
1 1
1 - 1 - 1 - 1
COAL (TON)
OB (BCM) 10.498
47.643 10.498
47.643 10.498
32.300 10.498
32.300 4.310
13.260 46.300
173.145
OVERWINNING
COAL BURDEN
PC 400 7 7 7 7 7
PC 300 1 1 1 1 1
SL DAEWOO
COAL (TON) 10.4982 2
10.498 2
10.498 2
10.498 4.3102 46.300
Hy SL 450 1 1 2 2 2
OVER BURDEN
P8500 Bk06 OB (BCM) 143.735 143.735 143.735 143.735 59.007 633.947
PC 400 7 7 7 7 7
COAL WINNING
SL DAEWOO 2 2 2 2 2
CAT 330
Hy SL DL
450 1 1 1
2 1
2 21
PCOB (BCM)
200 (coal) 143.735
0,5 143.735
0,5 143.735
0,5 143.735
0,5 59.007
0,5 633.947
COAL
COAL (TON)
WINNING 13.728 13.728 13.728 13.728 5.636 60.546

CAT 330 DL 1 1 1 1 Total OB 1 807.092

PC 200 (coal) 0,5 0,5 0,5 0,5 0,5
Total Coal 106.845
COAL (TON) 13.728 13.728 13.728 13.728 5.636 60.546
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Total OB 807.092
 S E
CA
 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

CASE - PROBLEM

CT loader : 30 detik/swing
Capacity : 6.3 m3 CT Hauler : 20 menit
Fill Factor : 0.95 Capacity hauler : 55 LCM
FK loader : 0.7 FK hauler : 0.75

?
PA : 90 %
UA : 65 %

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Schedule time : 720 jam/bulan
% swell : 1.25

Berapa kebutuhan Loader dan Hauler

untuk memenuhi target produksi sebesar 325,000 BCM/bulan
 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

CASE - TIPS

PL = bucket capacity x fill factor x 3600 x FK

cycle time

Prod = unit production x PA xUA x Schedule time

Kebutuhan unit loader = target produksi/bulan

Prod unit/bulan

PH = vessel capacity x 60 x FK
cycle time

Prod = unit production x PA x UA x Schedule time

Kebutuhan unit hauler = target produksi/bulan

Prod unit/bulan
 Small Class Training - Estimating Production by Unit Capacity – 22 Jan 2010

CASE - SOLUTION

Target Prod 325.000 BCM = 325.000 x 1.25 = 406.250 LCM

PL = bucket capacity x fill factor x 3600 x FK = 6.3 x 0.95 x 3600 x 0.70
cycle time 30
PL = 502.74 LCM/jam

Prod = unit production x PA xUA x Schedule time

= 502.74 x 90% x 65% x 720
= 211754.08 LCM/bulan

Kebutuhan unit loader = target produksi/bulan = 406.250 LCM

Prod unit/bulan 211756.08 LCM

Kebutuhan unit loader = 1.918 ≈ 2 unit

PH = vessel capacity x 60 x FK = 55 x 60 x 0.75

cycle time 20
PH = 123.75 LCM/jam

Prod = unit production x PA x UA x Schedule time

= 123.75 x 90% x 65% x720
= 52123.5 LCM/bulan

Kebutuhan unit hauler = target produksi/bulan = 406.250 LCM

Prod unit/bulan 52123.5 LCM

Kebutuhan unit hauler = 7.793 ≈ 8 unit

THANK YOU