Pragma | Case Studies | Delmas Coal Mine


Click here for the pdf version Click here to return to PRAGMA website Client Quote "With the inefficiencies in materials management and the substandard maintenance regimes that have been accepted as a norm in the mining sector, Pragma has assisted with the change of that culture. The competence and determination of the Pragma staff is making this work which is still in progress realisable" Mpumelelo Saliwa - General Manager Pragma Africa Northern Regional Manager Manufacturing & Mining Johannes Coetzee Tel: +27 11 318 0641 Fax: +27 11 316 0666 Cell: +27 82 447 7999 Johannes.coetzee@pragmaworld.net	Client Background Delmas Coal is a BEE-owned mine situated some 20km south of Delmas. It consists of a vertical shaft (South Shaft) and an inclined shaft which is used for machine access and recovering mined coal via a conveyor. 4 seam is mined using the traditional board and pillar method with three continuous miners. On surface there are a number of beneficiation plant options which allow Delmas to process coal to specific client needs in terms of grading and ash content/CV. Outbound logistics are via road and a dedicated rail siding.

	Key challenges / Project background Delmas Coal had been run down over many years of low energy prices and there had been very little investment in the plant and equipment. Maintenance had at times over the years been neglected. With the surge in demand for coal, the mine became viable again for at least the next 10 years and this required a change in maintenance strategy to ensure optimal asset performance over this period. Many of the maintenance systems that were in place were largely manual -- on paper or Excel. This allowed only limited management and control of the work and almost no ability to mine the maintenance data for focused improvement activities. The purchasing and stores systems were also largely paper driven and this resulted in frustrations for the users and long delays, which of course increased downtimes for the plant while waiting for spares. The PRAGMA intervention Pragma started at Delmas by performing an Asset Management Improvement Process (AMIP) assessment and from this a policy, strategy and improvement plan were drawn up. Key performance indicators were agreed upon and reports were developed to track these. Pragma implemented the ACC service by setting up on-site offices and implementing a full maintenance management system on On Key so that work could be identified, planned and allocated. Detailed feedback for each job is recorded. The store underwent a "5S" intervention which resulted in the disposal of huge amounts of scrap that had accumulated over the years, the redesign of the store itself, the redesign of the purchasing and stores processes and the implementation thereof on On Key. A specific solution was designed to enable efficient distribution of spares to the underground areas. In addition an efficient process was designed and implemented to manage rotable (repairable) items. A mining-specific solution was also implemented in On Key to measure overall productivity of the underground sections (including availability and utilisation) to address the shortcomings of the Overall Equipment Efficiency (OEE) methodology in the mining industry. Pragma participates in the Asset Management governance structures at Delmas and provides expert advice to the Asset Management team. As part of its strategic inputs, Pragma conducts an annual AMIP assessment and leads the development of an annual revision of the Asset Management Strategy. Busine Processes & Best Practices The following key business processes were implemented: Asset Care Foundations Asset Register Administration Warehousing Equipment Performance Measurement Asset Management Improvement Process (AMIP) Maintenance Plan Development Work Planning and Control	Performance Improvement Key benefits Single point responsibility for all maintenance work, from A to Z Standardised work planning & control processes across the whole operation. Accurate and complete asset register with history of work done Improved maintenance tactics Powerful analytical capability on work history Accurate productivity information on the mining machinery Efficient stores and purchasing. The BOTTOM LINE More efficient and cost- effective maintenance Steady improvement of equipment downtime and reliability Improved availability due to better spares service Better control of and information on the mobile mining fleet Cash generated from the sale of scrap from 5S exercise.