Kestrel Coal Mine Extension Project
A LEAN Case Study
April 2014
KME, LEAN Case Study
KME Project Location
Sunny Australia
Emerald
April 2014
KME, LEAN Case Study
Kestrel Coal Mine - Location
Kestrel Coal Mine
April 2014
KME, LEAN Case Study
Background
The Kestrel Coal Mine Extension Project is located in the Bowen
Basin 40 kilometres north east of Emerald in central Queensland.
The KME project is adjacent to the existing Kestrel coal mine
currently producing around 5.5 mtpa of high quality coking and
thermal coal using the Longwall extraction method.
The KME project is constructing a new mine, Kestrel South to access
the 400/500 series of longwall coal panels in the German Creek coal
seam.
It will mine 6.5mtpa for a 30 year mine life.
April 2014
KME, LEAN Case Study
Background
Projected cost = $2.0 Billion
Key Work Packages
Twin drifts, 1 x Conveyor, 1 x Transport
Sinking of Ventilation Shaft
Supply and install Ventilation fans
Pit bottom dewatering program
Pit bottom development of mine infrastructure and longwall panels
Construction of 550 mega litre site storage dam and sediment dams
Construction of 7km conveyor to Kestrel
Up grade of CHPP plant at Kestrel
Construction of 380 bed accommodation camp
Longwall and associated equipment procurement
April 2014
KME, LEAN Case Study
KME Layout
Drifts
Vent Shaft
Longwall Panels
Pit Bottom
April 2014
Gate Roads
KME, LEAN Case Study
Drifts - Specifications
Conveyor Drift
1577 metres long at a Gradient of 1:6
Arch profile 6.5m wide x 4.75m high.
Concrete segment floor.
Transport Drift
1876 metres long at a Gradient of 1:8
Arch profile 6.0m wide x 4.5m high.
Concrete segment floor.
April 2014
KME, LEAN Case Study
Drifts - Conveyor
Conveyor Drift: Intersects 6 coal seams
April 2014
KME, LEAN Case Study
Drifts - Conveyor
Conveyor Drift
April 2014
KME, LEAN Case Study
Drifts - Transport
Transport Drift - (Support class 1)
April 2014
KME, LEAN Case Study
Drifts - Construction
There have been 4 methods of construction to date in each drift.
Method 1:
Box cut excavated then structural concrete arches and floor
segments constructed and backfilled.
Method 2:
Hydraulic excavator cuts 1.3 metres of advance, spray 75mm
of fibre reinforced shotcrete (FRS), one ring of 2.4m Swellex
rockbolts, Steel arch sets at 1.0m centres, Sets fully encased
in fibre reinforced shotcrete. (Support class 4)
April 2014
KME, LEAN Case Study
Drifts Cut & Fill
Conveyor Drift Method 1 Cut & Fill
April 2014
KME, LEAN Case Study
Drifts - Construction
Method 3:
Geotechnical evaluation then determined the location to
discontinue the steel sets and switch to rings of 2.4m full column
resin rockbolts installed with a Jumbo and 75mm of fibre
reinforced shotcrete. (FRS)
Excavation continued with the hydraulic excavator fitted with a
quick hitch to allow the use of the bucket or a rock breaker.
(Support class 2)
April 2014
KME, LEAN Case Study
Drifts Steel Sets
Drift Construction Method 2 Steel Sets
April 2014
KME, LEAN Case Study
Drifts - Construction
Method 4:
A Mitsui S200 Road Header was then introduced.
This machine is fitted with an oscillating cutting head and chain conveyor
a shotcrete boom and a rock bolting boom.
It works in conjunction with a sliding floor mechanism that follows the
Road Header and contains the power packs, hydraulic vent duct erector,
vent extension can and the bridge conveyor.
Behind the bridge conveyor is the main conveyor to surface that removes
the spoil from the face.
(Support class 2), 2.4m Resin anchored rockbolts at 1.3m ring spacing
with 75mm of FRS.
(Support class 3), In coal seams 3.0m resin anchored rockbolts and
120mm FRS
April 2014
KME, LEAN Case Study
Mitsui S200 Road Header - Attachments
Bolter
Shotcrete boom
Shotcrete
Controls
(Swing out)
April 2014
KME, LEAN Case Study
Case Study KME Drift Construction
Conveyor Drift Cut with Mitsui S200 Road Header
April 2014
KME, LEAN Case Study
Road Header
75mm FRS
2.4m Resin Anchor Rockbolts
Exhaust Ve
nt
Bridg
e
Conv
e
ilation
yor
Sliding Floor
Road Header and sliding floor
April 2014
KME, LEAN Case Study
Road Header Sliding Floor
Vent Duct
(Exhaust)
Conveyor sends
Material to Surface
Bridge Co
n
veyor
Clean air
Conveyor Boot End
Pre Cast Concrete floor segments
April 2014
Sliding Floor
KME, LEAN Case Study
Drifts Concrete Floors
Concrete floor segments
Drift Cross Section
April 2014
KME, LEAN Case Study
Drifts Concrete Floors
Shotcrete infill
Precast Concrete floor segment
Grout
Concrete Nib Poured ahead of
the sliding floor
April 2014
Concrete blinding
KME, LEAN Case Study
Drifts Concrete Floors
Grout injection holes
Precast concrete floor
segments
6.0m x 1.3m x5.2 Tonne
Placement with LHD
April 2014
KME, LEAN Case Study
Drifts Concrete Floors
Lifting Lug
Nib
Non slip exposed aggregate
surface
Blinding Concrete
Segments in place
April 2014
KME, LEAN Case Study
Recognising the Problem !!!!
Plan
Actual
April 2014
Actual v Contract Baseline Conveyor Drift Progress
KME, LEAN Case Study
Improvement Cycle
Get the facts
Concern
Strips
Monitor
Process Maps
Drifts
Improvement
Plan
April 2014
Interrogate Data
EFU Graphs
KME, LEAN Case Study
Interrogate the Data
Start Up
Water, mud, floor issues
First Coal Seam
Familiarisation
Steady State,Clay
Mudstones
April 2014
KME, LEAN Case Study
Sandstone
Visualise the Cycle
Cycle times are vital to our goal
of continuous improvement
Each element of each cycle has
a target time that has been
agreed by the team as realistic
and achievable
Process Maps - Conveyor Drift Cycle Times
April 2014
KME, LEAN Case Study
Cycle Time Process Map
Green Under Time, Red Over Time
April 2014
KME, LEAN Case Study
LEAN - Effective Face Utilisation
To assist us to analyse the cycle time data we use a
measurement known as EFU
Effective Face Utilisation
Operating Time (OT)
=
%
Calender Time (CT)
EFU: Is the ratio of operating time to calendar time reported as a percentage
It is used to measure the effectiveness of the work being carried out at the
face.
It is NOT a try hard measure
April 2014
KME, LEAN Case Study
KME - Conveyor Drift - EFU
This graph demonstrates the direct correlation between EFU
and meters advanced
50% - 60% EFU
= 14 to 18 mpw
60% - 70% EFU
= 18 to 24 mpw
Best:32mpw
40% - 50% EFU
= 10 to 14 mpw
Steady state
Coal seams, mud, Mechanical issues
April 2014
KME, LEAN Case Study
Drifts Progress Improvement Plan
DRIFTS PROGRESS IMPROVEMENT PLAN
INITIATIVE
DUE
DATE
RESPONSIBI
LITY
Alternative Road Header or
Continuous Miner eg.AM105,
MB650
31/05/2
010
KME/Redpath
Standardise Face Cut
Competency
31/05/2
010
Redpath
Training Package Being Developed
Redpath
One cutting head has been returned to OEM
specification, will be fitted on next head change
out day
Pick design on Pineapple
April 2014
31/05
2010
STATUS as at 27/05/2010
Report to be prepared by Con Panidis and Katrina
Nobes for review Friday 27/1/2010
KME, LEAN Case Study
Drifts Progress Improvement Plan
Increase Cutting Power
from 200kw to
300kw
31/06/
20
10
Redpath
Not feasible, major structural and electrical
work required that can not be done at
the face.
Review Maintenance
Practices
31/05/
20
10
Redpath
Road Header specialist engaged,
maintenance schedule developed,
review of critical spares completed,
review maintenance resources, look at
24hr maintenance Superintendent
coverage
Brain Pump
17/05/
20
10
Redpath
Pump trialled and found to be unsuitable.
Supervac Guzzler
25/05/
20
10
Redpath
Pump on site, risk assessments completed,
ready for trial
Longitudinal Borehole
Below Conv. Drift
1/05/2
01
0
KME
Discarded, not technically possible and rig
not available.
April 2014
KME, LEAN Case Study
Drifts Progress Improvement Plan
Bert Holes close to face
31/05/
20
10
Vertical Drain holes into
coal seams
31/05/
20
10
Control of Outbye Water
April 2014
31/05/
20
10
Redpath
KME
Redpath
Suitable drilling rig being sourced
Feasibility, planning and availability
underway, environmental approvals
required.
*Drill rings of 6m relief holes in wet areas
below the first coal seam. Will be marked
up and trial holes to be drilled over the
weekend.
*Key way has been cut in the Conveyor
Drift which will allow us to install the
cattle grate sump as soon as the floor
moves down to that position. This will
control water post Aquila col seam
*Supavac Guzzla pump is on site and will
be commissioned this weekend.
*Auger to enable us to trial Bert holes
forward of the floor is being sourced.
*Hessian sand bags and sand have been
delivered to site,same goes for 4 by pallets
of stonedust for dam building.
*6 by new rollcage diaphragm pumps
have been ordered (due w/e 4/6/2010)
*Van ruth plugs ordered for stand pipes.
*Superintendents have been instructed to
place close focus on water management at
the face. Directing outbye water to sumps
is of major importance.
KME, LEAN Case Study
Information Centres - KME
Information Centre will display
Measures and metrics for your
areas
Equipment status
Targets for the team
Concern strips (how the problems
could be fixed)
Schedules and planning boards
Information about the project or
things that affect the teams work
Celebrate Success
Kestrel Coal Mine Extension Project Emerald Qld
April 2014
KME, LEAN Case Study
KME Project Concern Strips
April 2014
KME, LEAN Case Study
LEAN Where to from here??
April 2014
We need your feedback and
knowledge of the issues.
Your whole crew should be aware
of our targets and how long the last
cycle took.
Your Superintendent should
discuss our progress in the cycle
with you at your shift start meeting.
Issues will be raised on the LEAN
board where you will be able to
track their progress.
Implement and monitor the Drifts
Progress Improvement Plan.
KME, LEAN Case Study
Progress Improvement
30 m Clawed Back
260m Behind
Weekly targets achieved
LEAN Implemented
The worm starts to turn
Actual v Contract Baseline
Progress slump arrrested, meeting weekly targets and pulling a bit back
April 2014
KME, LEAN Case Study
MB650 Continuous Miner
April 2014
KME, LEAN
Case Studyon site
MB650 Continuous Miner
arrives
LEAN - Summary
LEAN will not work without the commitment and drive from LEAN
Leaders.
LEAN involves the whole workforce.
Waste is easier to understand and remove the closer we are to
where it is created.
Implementing Lean is simple but it aint easy
April 2014
KME, LEAN Case Study
Whats in it for Me?
A safe and productive work place with job satisfaction.
A valuable employee with skills and a continuous improvement mind
set.
A system to improve productivity has the flow on effect of improving
your bonus.
Project completed on time and budget means your company
becomes a contractor of choice for the mining industry.
Your Employer cant do it without skilled and committed workers. I hope they
Man, I love
this LEAN
dont break
anything
today
zzzz
zzzz
Safe and happy workers
April 2014
KME, LEAN Case Study
