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101025 Excellence in Exc Planning Presentation E Heiland

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The document describes the excavator planning process at Drayton Mine in Australia. It involves 8 steps: 1) mine activity design, 2) 16 week schedule, 3) monthly operating plan design review, 4) MOP delivery plan meeting, 5) excavator plan sign off process, 6) weekly plan process and pack, 7) daily pit communication, and 8) dig area reviews. The comprehensive process focuses on long-term and short-term planning, communication, and continuous improvement to efficiently uncover coal while ensuring safety.

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1 EXCELLENCE IN EXCAVATOR PLANNING AT DRAYTON MINE FROM THE DESIGN TO THE IMPLEMENTATION IN THE FIELD Erik Heiland Anglo American Metallurgical Coal Australia

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COAL 2 CONTENTS • Locality and Background Information • The Excavator Planning Process • Conclusion

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COAL 3 LOCALITY AND BACKGROUND INFORMATION

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COAL 4 LOCALITY • Hunter Valley/ New South Wales • One of AAMC’s most challenging operations • Operation began in 1983 • Scheduled production in 2010: 5Mt of thermal coal – 4Mt for export market – 1Mt for domestic market (Liddell and Bayswater power stations) Map of Region

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COAL 5 MINING EQUIPMENT • Major Mining Equipment – One BE1370 dragline – Two Hitachi EX5500 excavators – One Hitachi EX3500 excavator – Two front end loaders (Le Tourneau L1100 and L1400) – 24 Caterpillar 789B and C trucks • 67% of Drayton’s prime overburden is planned to be moved by Hitachi EX5500 excavators • Aim: Uncover coal in the safest and most efficient way in accordance with the business plan schedule BE1370 Dragline Excavator 305

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COAL 6 COMPLEX GEOLOGY • Deposit consists of five major seam groups with up to 40 splits • Major geological features are: – 45 to 60 degree steep dipping coal seams – Up to 40m faults – 100m thrust plane – Dykes – Intrusions • Geology creates tough working environment for the machinery Drayton Mine Seam Split Diagram

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COAL 7 COMPLEX GEOLOGY CONT. • Thrusting and Faulting create a major challenge for the mining operation • Drayton has a 100m thrust plane running through the deposit Diagrammatic Representation of Normal Faulting and Thrust Faulting Balmorals

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COAL • An Example: South Pit East • Thrust plane, 10 faults, seam splitting, fill, spon com… 8 COMPLEX GEOLOGY CONT. Diagrammatic Representation of Normal Faulting and Thrust Faulting Representative Cross-Section Through South Pit East, October 2010 Thrust plane SectionAB A B Faults shown in black Faults These are the same Grasstrees seams

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COAL 9 BENCHMARK PERFORMANCE • Drayton’s excavator fleet delivers benchmark performance within AAMC • EXC306 and 307 are ranked No. 1 and 2 in its category • Major Key Performance Indicator: Operational Equipment Efficiency AAMC Operational Efficiency Ranking, Above 500t Excavator Category, August 2010

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COAL 10 THE EXCAVATOR PLANNING PROCESS

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COAL 11 THE EXCAVATOR PLANNING PROCESS • Process includes eight process steps • Bullet point 2 • Bullet point 3 • Bullet point 4 • Bullet point 5

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COAL 12 MINE ACTIVITY DESIGN (MAD) • Compliance with AAMC Operations Management System • Focus on the long term, medium term and short term planning, actual production and reconciliation • MAD document focuses on the 18-month planning process The AAMC Mine Planning Process

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COAL 13 16 WEEK SCHEDULE • Visual representation of equipment path for the Dragline and two EX5500 Excavators • Purpose of schedule – Identification equipment interactions – Input data for the 16 week drill and blast schedule – Determination of coal uncovered dates for the coal and partings schedule – Identification of short term truck shortages or excess The 306 Excavator Path in the 16 Week Schedule

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COAL 14 MONTHLY OPERATING PLAN (MOP) DESIGN REVIEW • Review of excavator designs for the following month • Determination of average monthly dig rate per excavator for input in schedule • Optimisation of dig plans • Presentation of plans by the excavator engineer One of Tony’s pics Visualisation of the EN03 Broughams dig area

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COAL 15 MOP DELIVERY PLAN MEETING • Identification of critical issues • Ensure the monthly Key Performance Indicators are achieved • Assign actions and agree on due dates Key Performance Indicator: Prime, Monthly Delivery Plan, September 2010

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COAL 16 EXCAVATOR PLAN SIGN OFF PROCESS • E = Q x A [Effectiveness = Quality x Acceptance] • Ensure that final design plans contain the most up to date information • Import of actual drilling data to deliver most accurate coal surface • Sign off to be completed one week before an excavator enters the work area Sign off for SPW09-10P and SPW08G dig

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COAL 17 WEEKLY PLAN PROCESS AND PACK • Weekly Plan Process includes a pre-planning meeting and a planning meeting • Agree on the weekly equipment path, blast and mining sequence, equipment interaction • Weekly plan pack is a comprehensive package which is sent via E-mail to all relevant mine personnel Weekly Plan Excavator Path, Plan commencing 7 October 2010

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COAL 18 DAILY PIT COMMUNICATION • Pit inspections are conducted a minimum of three times a week • Communication of the plan to front line personnel • Inspection of current and future dig and dump areas during the tour • Supervisor’s light vehicle and four bull dozers are equipped with a GPS • Video GPS in Supervisors light vehicle – SPW09P12 dig area

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COAL 19 DAILY PIT COMMUNICATION • Minimum three times a week • Communication of the plan to front line personnel • Inspection of Current and future dig and dump areas are inspected during the tour • Supervisor’s light vehicle and four bull dozers are equipped with a GPS • Video NN10 East - Excavator N Shot to be fired Fired on 26/06 Vol remaining: 735kBCM Trucks: 7 Target seam: RL Dig Sequence 1) Continue 4.5m BSL pass from East to West to form Ramp on Northern side 2) Come off the Ramp and BSL 4.5m passes uncover unshot material from West to East USE MATERIAL TO COVER FIRES IN SS WHEN TRUCKING AVAILABLE BLOCKY MATERIAL IN THE SOUTH OF THE DIG AREA GPS FILE: NN10-190 Dump Level 7-RL295, GPS-File: LV7REH 1 2 Unshot material to be uncovered 70Deg PS wall 45Deg Softwall Haul route to East Ramp Application of 3D Dig Software in the NN Pit

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COAL 20 DIG AREA REVIEWS • Dig reviews are carried out within one month after completion of the dig • Reconciliation of planned vs. actual performance • Key learning outcomes are identified and actions assigned • Learning outcomes are included into the next MAD document Excavator Dig Reconciliation

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COAL 21 CONCLUSION

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COAL 22 CONCLUSION Excavator Planning at Drayton is very comprehensive process Key reasons for success: – Customer focus and having good working relationships – Input from experienced Production personnel in the planning process – Use of direct communication – Accurate tracking of Key Performance Indicators – Compliance with Operations Management System

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COAL 23QUESTIONS? “THE WAVE” IN THE NN PIT BW NE Steep dip

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101025 Excellence in Exc Planning Presentation E Heiland

  • 1. 1 EXCELLENCE IN EXCAVATOR PLANNING AT DRAYTON MINE FROM THE DESIGN TO THE IMPLEMENTATION IN THE FIELD Erik Heiland Anglo American Metallurgical Coal Australia
  • 2. COAL 2 CONTENTS • Locality and Background Information • The Excavator Planning Process • Conclusion
  • 4. COAL 4 LOCALITY • Hunter Valley/ New South Wales • One of AAMC’s most challenging operations • Operation began in 1983 • Scheduled production in 2010: 5Mt of thermal coal – 4Mt for export market – 1Mt for domestic market (Liddell and Bayswater power stations) Map of Region
  • 5. COAL 5 MINING EQUIPMENT • Major Mining Equipment – One BE1370 dragline – Two Hitachi EX5500 excavators – One Hitachi EX3500 excavator – Two front end loaders (Le Tourneau L1100 and L1400) – 24 Caterpillar 789B and C trucks • 67% of Drayton’s prime overburden is planned to be moved by Hitachi EX5500 excavators • Aim: Uncover coal in the safest and most efficient way in accordance with the business plan schedule BE1370 Dragline Excavator 305
  • 6. COAL 6 COMPLEX GEOLOGY • Deposit consists of five major seam groups with up to 40 splits • Major geological features are: – 45 to 60 degree steep dipping coal seams – Up to 40m faults – 100m thrust plane – Dykes – Intrusions • Geology creates tough working environment for the machinery Drayton Mine Seam Split Diagram
  • 7. COAL 7 COMPLEX GEOLOGY CONT. • Thrusting and Faulting create a major challenge for the mining operation • Drayton has a 100m thrust plane running through the deposit Diagrammatic Representation of Normal Faulting and Thrust Faulting Balmorals
  • 8. COAL • An Example: South Pit East • Thrust plane, 10 faults, seam splitting, fill, spon com… 8 COMPLEX GEOLOGY CONT. Diagrammatic Representation of Normal Faulting and Thrust Faulting Representative Cross-Section Through South Pit East, October 2010 Thrust plane SectionAB A B Faults shown in black Faults These are the same Grasstrees seams
  • 9. COAL 9 BENCHMARK PERFORMANCE • Drayton’s excavator fleet delivers benchmark performance within AAMC • EXC306 and 307 are ranked No. 1 and 2 in its category • Major Key Performance Indicator: Operational Equipment Efficiency AAMC Operational Efficiency Ranking, Above 500t Excavator Category, August 2010
  • 11. COAL 11 THE EXCAVATOR PLANNING PROCESS • Process includes eight process steps • Bullet point 2 • Bullet point 3 • Bullet point 4 • Bullet point 5
  • 12. COAL 12 MINE ACTIVITY DESIGN (MAD) • Compliance with AAMC Operations Management System • Focus on the long term, medium term and short term planning, actual production and reconciliation • MAD document focuses on the 18-month planning process The AAMC Mine Planning Process
  • 13. COAL 13 16 WEEK SCHEDULE • Visual representation of equipment path for the Dragline and two EX5500 Excavators • Purpose of schedule – Identification equipment interactions – Input data for the 16 week drill and blast schedule – Determination of coal uncovered dates for the coal and partings schedule – Identification of short term truck shortages or excess The 306 Excavator Path in the 16 Week Schedule
  • 14. COAL 14 MONTHLY OPERATING PLAN (MOP) DESIGN REVIEW • Review of excavator designs for the following month • Determination of average monthly dig rate per excavator for input in schedule • Optimisation of dig plans • Presentation of plans by the excavator engineer One of Tony’s pics Visualisation of the EN03 Broughams dig area
  • 15. COAL 15 MOP DELIVERY PLAN MEETING • Identification of critical issues • Ensure the monthly Key Performance Indicators are achieved • Assign actions and agree on due dates Key Performance Indicator: Prime, Monthly Delivery Plan, September 2010
  • 16. COAL 16 EXCAVATOR PLAN SIGN OFF PROCESS • E = Q x A [Effectiveness = Quality x Acceptance] • Ensure that final design plans contain the most up to date information • Import of actual drilling data to deliver most accurate coal surface • Sign off to be completed one week before an excavator enters the work area Sign off for SPW09-10P and SPW08G dig
  • 17. COAL 17 WEEKLY PLAN PROCESS AND PACK • Weekly Plan Process includes a pre-planning meeting and a planning meeting • Agree on the weekly equipment path, blast and mining sequence, equipment interaction • Weekly plan pack is a comprehensive package which is sent via E-mail to all relevant mine personnel Weekly Plan Excavator Path, Plan commencing 7 October 2010
  • 18. COAL 18 DAILY PIT COMMUNICATION • Pit inspections are conducted a minimum of three times a week • Communication of the plan to front line personnel • Inspection of current and future dig and dump areas during the tour • Supervisor’s light vehicle and four bull dozers are equipped with a GPS • Video GPS in Supervisors light vehicle – SPW09P12 dig area
  • 19. COAL 19 DAILY PIT COMMUNICATION • Minimum three times a week • Communication of the plan to front line personnel • Inspection of Current and future dig and dump areas are inspected during the tour • Supervisor’s light vehicle and four bull dozers are equipped with a GPS • Video NN10 East - Excavator N Shot to be fired Fired on 26/06 Vol remaining: 735kBCM Trucks: 7 Target seam: RL Dig Sequence 1) Continue 4.5m BSL pass from East to West to form Ramp on Northern side 2) Come off the Ramp and BSL 4.5m passes uncover unshot material from West to East USE MATERIAL TO COVER FIRES IN SS WHEN TRUCKING AVAILABLE BLOCKY MATERIAL IN THE SOUTH OF THE DIG AREA GPS FILE: NN10-190 Dump Level 7-RL295, GPS-File: LV7REH 1 2 Unshot material to be uncovered 70Deg PS wall 45Deg Softwall Haul route to East Ramp Application of 3D Dig Software in the NN Pit
  • 20. COAL 20 DIG AREA REVIEWS • Dig reviews are carried out within one month after completion of the dig • Reconciliation of planned vs. actual performance • Key learning outcomes are identified and actions assigned • Learning outcomes are included into the next MAD document Excavator Dig Reconciliation
  • 22. COAL 22 CONCLUSION Excavator Planning at Drayton is very comprehensive process Key reasons for success: – Customer focus and having good working relationships – Input from experienced Production personnel in the planning process – Use of direct communication – Accurate tracking of Key Performance Indicators – Compliance with Operations Management System
  • 23. COAL 23QUESTIONS? “THE WAVE” IN THE NN PIT BW NE Steep dip