6979(Print), ISSN (Online), Volume 6, Issue 1, January- April (2015), pp IAEME RESEARCH AND DEVELOPMENT (IJIERD)

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1 INTERNATIONAL International Journal of Industrial JOURNAL Engineering OF Research INDUSTRIAL and Development ENGINEERING (IJIERD), ISSN 976 RESEARCH AND DEVELOPMENT (IJIERD) ISSN (Print) ISSN (Online) Volume 6, Issue 1, January April (2), pp IAEME: IJIERD.asp Journal Impact Factor (2):.996 (Calculated by GISI) IJIERD I A E M E IDLE TIME ANALYSIS OF MINING EQUIPMENT USING PARETO PRINCIPLE A CASE STUDY M.E.Michael Arputharaj Deputy Chief Engineer / Mining, Neyveli Lignite Corporation Ltd, Tamilnadu ABSTRACT Loss of operation time due to idleness of machine is no longer affordable to mine management in recent years. So it is required to maximize the return on investment of equipment by optimizing its utilization. It is generally found that there is a wide gap between availability of a equipment for operation and utilization. So analysis of idle time of equipment may serve as basis of information that can be used by mine management to make effective decision to improve machine operation time. In this paper, the cause of gap betwneen availability and utilization of equipment have been studied. Operational behavior and possible causes of idle time are analyzed cause wise by Pareto diagram and appropriate conclusion has been drawn on the basis of the outcome of the analysis. Keywords: Performance, Pareto Principle, Utilisation, Idle State. 1. INTRODUCTION Pareto technique helps to identify the major causes that need to be identified to resolve the majority of problems. In simple terms, Pareto priciple states that 2 % of the causes are responsible for 8 % of the problems. So it is necessary to identify those 2 % of the root causes to solve major problems. With this principle, the root causes of the equpment idle time are analysed to reduce the machine idle hours to a major extent. 14

2 2. IDLE STATE ANALYSIS Cause of machine idle time have been categorized as Managerial Inlcudes blasting time and daily machine inspection time. Operators causes Inlcudes idle time due to want of operator Machine marching Includes time spent in moving the machine from workshop to mine and from mine to workshop and also shifting the machine with in the mine. Non availability of matching equipement Includes time lost due to want of shovel or shovel under repair Miscellaneous Inlcude leveling work at haul roads, safety week celebration and taking photograph for website etc. Pareto principle, applied to machine behaviour, suggests that significant few causes are responsible for majority of idle time of machine and trivial many problems play only a small part in the overall machine idleness. The equipment are stopped for about minutes for blasting and for 3 minutes for tiffin/ tea break. Shift start, ends and moving machinery from workshop to mine and from time to workshop take about one hour in a shift. The stoppage of dumpers for want of shovel and shovel under breakdown has been considered. The contribution of various causes towards machine idle state has been given in table 1. Table1. Idle State Analysis S.no Cause of idle state Shovel (%) Dumper (%) Dozer (%) 1 Machine check Moving machine from workshop to mine Blasting Tiffin / tea break Want of operator Machine shifting Moving machine from mine to workshop Want to shovel Shovel under repair Miscellaneous The percentage contribution of various idle state causes towards total idle time in case of shovel, dumper and dozer has been shown using histogram in fig 1, fig 2 and fig 3 respectively.

3 Fig 1. Idle State Analysis of Shovel Fig 2. Idle State Analysis of Dumpers 16

4 Fig 3. Idle State Analysis of Dozer 3. SUGGESTIONS TO MINIMIZE IDLE HOURS The following steps can be taken to reduce the idle hours of equipment Purchasing on more shovel will reduce the dumper idle hours to a greater extent (around 3% ) but this decision has to be made after giving due considerations to the production requirements and doing cost benefit analysis. The idea of leaving the machine in the mine itself after the work is over can be thought of, if necessary The blasting operation can be done once in a day, instead of each shift to reduce the work stoppage due to blasting. Concentrating the work places in the mine instead of having scattered working will help to reduce the time lost in marching the equipment. The workshop personnel can check the machine before the shift starts. Thus the time spent by the machine operator in machine checking can be reduced. Locating the workshop very near to the mine will reduce the time spent lost in moving the machine from workshop to mine and from mine to workshop 4.CONCLUSION Idle state analysis using Pareto principle is an effective tool to reduce equipment down time, that too in the era of globalisation with cut throat competition. The views expressed in this paper are of the author and not necessarily of the organisation, he belongs to. 17

5 .REFERENCES 1. Samanta B., Banerjee J., and Sarkar B., 1999, Improvement in Utilisation of a Dragline in a Mine Using Idle Sate Analysis, The Indian Mining & Engineering Journal,February, Gillett, B.E., 1987, Operation Research, S.Chand and Company, New Delhi. 3. Bhattacharya M., 1972, Application of Industrial Engineering Techniques To Mining, Journal of Mines, Metals & Fuels,June, Levin, R.I., 1989, Statistics for Management-Fourth Edition, Prentice Hall of India Private Limited, New Delhi.. Sanjay Patel, Nitin Raval and Dr. K. Kotecha, A Novel Approach For Frequent Pattern Mining International Journal of Advanced Research in Engineering & Technology (IJARET), Volume, Issue 2, 214, pp. 2-6, ISSN Print: , ISSN Online: Inje Bhushan V. and Prof. Mrs. Ujwalapatil, A Comparative Study on Different Types of Effective Methods In Text Mining: A Survey International journal of Computer Engineering & Technology (IJCET), Volume 4, Issue 2, 213, pp. 3-42, ISSN Print: , ISSN Online: Rajesh V. Argiddi and Sulabha S. Apte, A Study of Association Rule Mining In Fragmented Item-Sets For Prediction of Transactions Outcome In Stock Trading Systems International journal of Computer Engineering & Technology (IJCET), Volume 3, Issue 2, 212, pp , ISSN Print: , ISSN Online: