UNDERSTANDING AVAILABILITY AND UTILISATION

AVAILABILITY AND UTILISATION IN THE CRUSHER SHIFT REPORTS Availability is defined as the percentage of time that a system or equipment is available to perform its required function or intended purpose. The availability is directly related to maintenance. This simply means that maintenance personnel have to ensure that the equipment (CV21) or system (FE02 system) is continuously running without any breakdown or reactive maintenance occurring. Example: If the Crusher is running 24 hours non-stop with no breakdown, it is available for use and its performing its function. We can say the crusher is 100% available (this is the percentage of time) In the daily shift reports it is essential to show the availability and utilisation of the 3 systems we have here at crusher; the FE02 system, the FE03 system and the Reclaim system so we know who is responsible for the downtimes in terms of availability and utilisation. Availability can be calculated simply by using the raw time captured, that is: Availability = Uptime Uptime + Downtime = Total hours for each shift Downtime hours X 100% Total time for each shift

Some of the downtime directly related to availability here at IPC includes Belt trips due to tracking issue only if it is directly related to defective impact rollers, frames, carriage trolleys, counterweight and misalignment of frames (mechanical defects). Conveyor belt stoppage due to damaged or split belt, bearing defects, shaft breakage, worn pulley lagging or defective roller and roller frames ( mechanical defects) Metal Detector stoppage of CV21 this downtime can only be seen as availability downtime if the metal detector detects loose liners, wear bars, bolts, etc that is a component of one of the equipment here at crusher. Stoppage due to haul truck wear plate, tooth, or any loose components of the mobile equipment from the mine must not be counted as availability downtime. This is beyond our IPC maintenance crews control so it is regarded as utilisation downtime. From these examples above we can clearly see that any equipment downtime in the system due to mechanical defects such as worn components and parts especially the components of the Crusher equipment is directly related to Availability Downtime. Example: FE03 system Defect FE05 counterweight rope snap Hole out on FE03 insert Total downtime = 5 hours Total hours per shift = 12 hours Total uptime = 12 5 = 7 hours uptime Availability = Uptime = Total hours Downtime hours = 7 hours = 0.5833 x 100%=58.33% Page 1 Downtime 3 hours 2 hours

NOTES BY: LORRAINE BALEPAI, GAusIMM & AMImechE

UNDERSTANDING AVAILABILITY AND UTILISATION

Uptime + Downtime Total time 12 hours

We can say availability for the FE03 system is 58.33% Avail (%)
FE03 SYSTEM STATUS DOWN UP DURATION 58%

Util (%)
Equipment Down Time Descriptions & Comments

FE03 CV24 SC01 FE04 FE05 CV25

Down

13:00

15:00

2:00

Hole out on FE03 insert

Down

6:00

9:00

3:00 5 hours

Counter weight rope snapped off.

Total Down/Delay Time

This example can be used for the other systems, FE02 and Reclaim system as well. Utilisation is defined by the use of the equipment by operations to produce the tonnage required when the equipment or system is available for use for its intended function This means when the equipment is 100% available, running continuously, it should be maximised by allowing the Run Of Mine (ROM) to pass through without any delays. Example: If the crusher is available 100%, the conveyor belts should be carrying 5500t/hr to maximise utilisation. Therefore averaging 60-66000 tonnes per shift The crusher daily shift report should capture utilisation as well. Some of the downtime, and stand by time directly related to utilisation here at IPC includes Standby/Delay time- blasting, shift changes, and weather (fog) Stoppages - due to spillage build up or sticky ore in chutes, dump pocket, pulleys, and rollers causing downtime and trips due to under speed Metal Detector stoppage of CV21 this downtime can only be seen as utilisation downtime if the metal detector detects skarn ore, or a component of one of the mobile equipment at the mine. That is stoppage due to haul truck wear plate, tooth, or any loose components of the mobile equipment from the mine and not from the crusher equipment From these examples above we can now differentiate between downtime due to Availability and Utilisation. Utilisation= Total hours-Downtime Hours-Standby hours Total hours-Downtime Hours Example: FE02 system NOTES BY: LORRAINE BALEPAI, GAusIMM & AMImechE Page 2 X 100%

UNDERSTANDING AVAILABILITY AND UTILISATION

Problem Blocked at CV22/23 chute by sticky ore Belt drift due to build up in chute on CV23 Heavy fog in pit ( stand by time) Downtime 30 mins 20 mins 2 hours

Total downtime = 50mins (convert mins to hours, 60 mins= I hour) Total standby time= 2 hours Total hours per shift = 12 hours Utilisation= Total hours-Downtime Hours-Standby hours Total hours-Downtime Hours X 100% = 12-(50/60)-2 X100%=82.09% 12-(50/60)

We can say utilisation for the FE02 system is 82.09% and availability is 100% Avail (%)
FE02 SYSTEM STATUS DOWN UP DURATION 100%

Util (%)
82.09 % Equipment Down Time Descriptions & Comments

FE02 CV19 GR02 CV21 CV22 CV23

Idle

13:00

15:00

2:00

Heavy fog in pit

Down/ Up

16:00 08:00

16:30 08:20

Total Down/Delay Time

0:30 0:20 2:15 hours

Blocked at CV22/23 chute by sticky ore Belt drift due to build up in chute on CV23

This example can be used for the other systems as well. These explanations will help your understanding of Availability and Utilisation and will also aid us in inputting improvement ideas in increasing the plant equipment efficiency and reduce the stoppages. For further clarifications do come and see me

NOTES BY: LORRAINE BALEPAI, GAusIMM & AMImechE

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