Case Study- Plan the work, work the plan
Plan the work,worktheplan (a case research primarily based on upkeep practices within the mining business) Case Examine- Plan the work, work the plan Gordon Dunbar Web page 2 Contents Plan the work, work the plan ……………………………………………………………………….1 1 Introduction and goal ……………………………………………………………………… 6 2 How ought to a scholar analyse this case?………………………………………………..6 three Setting the scene …………………………………………………………………………………9 four Background – metals and mining sector…………………………………………………..9 four.1 Specific characteristicsof the mining sector…………………………………..10 four.1.1 Excessive preliminary upfront funding –………………………………………………… 10 four.1.2 Distant places requiring lengthy life operation ……………………………. 11 four.1.three Excessive operational mounted to variable value ratio – ……………………………… 11 four.1.four Excessive capital depth ………………………………………………………………. 13 four.1.5 Value taker’s vs worth maker‘s ………………………………………………….. 14 four.1.6 Self-inflicted risky financial cycle?……………………………………….. 14 four.1.7 The problem of technique and upkeep alignment ………………….. 15 5 Upkeep in Mining……………………………………………………………………….. 15 5.1 What causes gear to fail?……………………………………………………..16 5.1.1 Age primarily based failure patterns ………………………………………………………. 16 5.1.2 Random primarily based failure patterns ………………………………………………… 17 5.2 Kinds of maintenancepractices……………………………………………………..18 5.2.1 Run-to-failure upkeep……………………………………………………… 19 5.2.2 Preventative upkeep ………………………………………………………. 19 5.2.three Predictive Upkeep– …………………………………………………………. 19 5.2.four Planning vs Scheduled upkeep ………………………………………… 20 5.three Reliability Centered Upkeep (RCM)…………………………………………21 5.four The importanceof upkeep……………………………………………………..22 5.four.1 Throughput …………………………………………………………………………… 22 5.four.2 Price …………………………………………………………………………………….. 23 5.four.three Capital funding ………………………………………………………………….23 5.four.four Licence to function …………………………………………………………………. 23 5.5 Thecurrentstate………………………………………………………………………….23 6 SystemsThinkingOverview………………………………………………………………..26 Case Examine- Plan the work, work the plan Gordon Dunbar Web page three 6.1 Overview of the Principle of Constraints…………………………………………….27 6.1.1 TOC physique of information ………………………………………………………….28 7 A ppendices………………………………………………………………………………………. 30 7.1 Temporary description of Heap Leach Copper operations…………………………..30 7.2 Glossary of phrases…………………………………………………………………………33 7.three Prime 40 mining firms ……………………………………………………………..34 7.four Mine site- gear checklist ……………………………………………………………….35 7.5 Manufacturing and upkeep statistics…………………………………………….36 7.6 Upkeep efficiency commonplace………………………………………………..37 7.1 Beneficial References ………………………………………………………….. 38 Case Examine- Plan the work, work the plan Gordon Dunbar Web page four Summary The case research is targeted on the operations of XYZ Restricted, a heap leach copper mine positioned within the Atacama desert in Chile. The timeframe is 2012 when copper costs and grade have been in decline with each finally conspiring to cut back returns to shareholders. A CEO has not too long ago been appointed and given an formidable goal to concurrently obtain a 15% enchancment in manufacturing of saleable product (copper cathode), a 20+% discount in working prices and a 20% discount in stock/investments. The operation mines copper from a measured useful resource of 100mt at a head grade of zero.5% copper. The ore to waste ratio is three:1. Restoration charges are within the order of 75% The method of changing mined ore to copper cathode entails mining the ore and waste from an open pit utilizing a fleet of drill rigs (15) dump vehicles (25) and (four) loaders. Overburden is stockpiled for future rehabilitation functions. In- situ waste is relocated to a sterilised web site throughout the mine and the ore is trucked to a ROM (Run of mine) stockpile positioned inside shut proximity of the first crusher. The ore is progressively crushed utilizing each jaw and cone model crushing gear and screened to attain a predefined particle dimension that facilitates an optimum floor space previous to agglomeration. Agglomeration leads to a consist separation of the fragmented particles to facilitate the leaching course of. Agglomerated ore is stacked onto current heap leach pads utilizing mechanical cell stackers and conveyor belts. The heap leach pads are constructed in a layered formation after which leached by way of a conveyable reticulation system which sprays the highest of the pad with sulfuric acid. Because the acid flows although the heap leach, the acid dissolves the copper and carries it by gravity to the bottom of the heap leach pad after which to irrigation channels positioned to the aspect of the pads the place the ‘pregnant’ resolution is diverted and finally directed into accumulation ponds. The pregnant resolution is topic to electro successful (EW) and solvent extraction (SX) the place the copper in resolution is transformed (by electrolysis) into copper cathode sheets as an finish product. The remaining resolution is cleaned and reused in future leaching course of.. The operation produces roughly 100,000t of copper cathode yearly The mine web site has been operating for roughly 20 years with a lot of the mounted plant (main, secondary and tertiary crushing, agglomeration stackers conveyors) infrastructure (buildings, energy traces, water pipes , roads and so on) and cell fleet (drill rigs, loaders, dump vehicles, gentle autos and so on) being topic to common preventive upkeep. Regardless of this, the extent of breakdown (unscheduled failure) stays excessive (~50+%) leading to surprising and hostile impacts on gear availability in addition to greater than regular value of repairs (due sometimes to the necessity to expediting elements and pay penalty labour/contractor charges to restore greater than regular injury). Case Examine- Plan the work, work the plan Gordon Dunbar Web page 5 The standard and amount of spare elements holdings is one other ongoing drawback for the operation. The quantity of spares required to be held for upkeep actions is unsubstantiated (in line with the CEO) and on the excessive aspect with a major share labeled as sluggish shifting. Sluggish shifting spares have a better probability of being topic to written off provisions and subsequently bought for scrap worth by the shop supervisor. Redundant spares additionally happens by way of gear being bought or scrapped with out together with the prevailing spare elements holding, ensuing in a gentle however rising accumulation of redundant and nugatory elements. That is additionally exacerbated by the engineering perform failing to determine technical requirements for the acquisition of varied sorts of gear. This leads to a large number of manufactured fashions (for instance) of dump vehicles, drill rigs, graders, pumps and so on all requiring their very own specialised elements, tooling and experience The tactic utilized by finance to account for the operations upkeep prices is one other space of concern. Direct upkeep elements and supplies when consumed, are charged on to the associated fee centre the place the gear belongs. Nevertheless, oblique upkeep prices reminiscent of labour, consulting and overhead (supervision, coaching and so on) are accrued and allotted on the premise of the % work orders executed in a given space in every month. Consequently, there is no such thing as a single supply of fact in respect to the overall value of upkeep, making it significantly tough to watch and due to this fact handle. It's broadly believed nonetheless that annual upkeep expenditure is a least half of the overall value of annual operations ($448m). POSTED ONMAY 21, 2018 Submission in a phrase doc. Embody acceptable BRE810 S217 Web page 1 of 1 Evaluation Merchandise three Analysis report The duty: Write a analysis report with regard to the subject you will have researched all through the unit. Your analysis report MUST comprise, and be structured in line with the next sections: • Cowl sheet • Desk of contents • 1. Introduction (analysis drawback, unit of investigation, analysis query, outlook) • 2. Literature Evaluate • three. Methodology • four. Findings and evaluation • 5. Suggestions and / or future analysis • 6. Conclusions • References ATTENTION: Your report will probably be checked for plagiarism (i.e. copy & paste / utilizing any materials from any type of supply with out referencing it correctly). Plagiarism will lead to a fail and may set off additional penalties. Description/Focus: Analysis report Worth: 45 % Due date: Midnight Sunday Week 12 Size: 3000 – 3500 phrases Job: See extra directions beneath. Presentation: Submission in a phrase doc. Embody acceptable headings; font Arial 11. CDU Harvard referencing model required. Submissions by way of Learnline by way of safeassign submission level.