ON TRACKDecember 2012

Inside:• Komatsu fleet “fast and efficient” at Palesa Colliery• Expanded Reman service on the cards• Komatsu supports special needs at GlenBridge School

Inside

Message from Komatsu Southern Africa’s Managing Director 1

Optimising after sales support

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Excavators at the heart of Leeupoort

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Sishen trucks show real steel

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Ultimate dozer

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Relay for life

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Wreckmasters

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Water for the nation

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Fast and efficient mining

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Unearthing treasures in our communities

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When I last wrote this column at the beginning of the year our financial performance in 2011 was underpinned by a steady and determined recovery of the mining industry following the recession years of 2009 and 2010. Who would have predicted then that a mere six months later the industry would be beset by violent and protracted labour unrest which would not only challenge the tenacity of the sector but have a significant impact on the South African economy as a whole.

The immediate effect of the industrial turmoil was a significant slow-down in the rate of economic growth in the third quarter but, in the long term, damage to South Africa’s reputation as a mining investment destination, coupled with a double-dip recession in the EU, a stuttering recovery in the United States and a slowdown in China, will no doubt have a ripple effect across the entire mining supply chain.

So what does that mean for Komatsu?

Now, more than ever, the strong principles of the KOMATSU Way, articulated by our founders in Japan more than 90 years ago, will guide the way we do business and help us to provide the support needed by our customer base in the challenging months ahead.

Allow me to expand on just a few of these key areas.

Customer orientedWe believe that strong relationship management is a fundamental principle for business success. Understanding and being able to respond quickly to the needs of our customers will enable them to be more productive and efficient. This applies not only to providing the best equipment for the job but also to ensuring the best after sales service and support. A clear example of this is the establishment of our new Parts Distribution Centre (PDC). We have completed the relocation of our parts inventory into the brand new 18 000m² warehouse which, coupled with a significant project to improve our inventory management processes, will ensure that we continue to improve our parts availability to meet the requirements of our customers.

Commitment to quality and reliabilityBy leveraging on the many years of experience in the industry and the strong support of our mother company in Japan, KSAf is well positioned to offer world class products and services.

Message from Komatsu Southern Africa’s Managing Director

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Mike Blom

Technology innovation Komatsu continues to invest in the research and development of leading- edge technology. Our equipment is designed and built to deliver at the lowest cost per ton in the most challenging applications and with as little impact on the environment as possible. Additionally, with advanced technology such as our satellite tracking and monitoring system, Komtrax, our customers are able to closely manage the performance of their fleets to achieve optimal levels of productivity, cost-efficiency and work schedule planning.

Human resource developmentOngoing training and skills development within our workforce is essential if we are going to be in a position to meet all of the commitments I have already mentioned, and remain competitive and relevant to the needs of our customers. Equipping our staff with the right technical skills is of particular importance and it is for this reason that we invest a significant amount of money in sending our technicians for specialist training at Komatsu mother plants around the world.

I have no doubt that 2013 will be a trying and demanding year for most but we are resolute in our commitment to working with and for our customers through these challenges. I wish you all a blessed and happy festive season and safe journeys if you are travelling.

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Fast and efficient mining

The mine supplies coal directly to Eskom and, despite the relatively low value per ton of the coal it produces, is able to extract enough efficiency to turn a profit and continue expanding the operation.

Mine manager, Dawid Ras, runs a tight operation with no room for errors: every person on site knows what is expected of them and machines are worked hard around the clock for six days a week.

Priority no 1He says efficiency and the reliability of equipment is of paramount importance. The fleet of exclusively Komatsu machines have worked tirelessly to shape the mine since it was reopened over three years ago.

With all mining activities undertaken by mining contractor Diesel Power, the mine’s own fleet of Komatsus are responsible for stockpiling and moving the raw coal to the various processing plants to ensure crushing, screening and washing processes run uninterrupted throughout the day. Loading road trucks and dumping waste is also undertaken by the fleet of two WA500 and WA480 wheel loaders, with hauling undertaken by three super-reliable HM400 ADTs.

Currently the mine processes 280 000 tons of raw coal per month. As a result of the reduced prices fetched for the lower grade coal produced at the mine, cost effectiveness of the operations is a priority for management. Plant manager, Gert van Niekerk, keeps a close eye on the operation and constantly moves machines to areas where they are needed most in order to keep the complex process running smoothly and efficiently.

Careful supervisionDue to its small footprint it is clear to see that there are no idling or even slow moving machines on the mine. “We use each machine for a number of tasks on the mine. Short distance stockpiling, clearing, loading and housekeeping are undertaken by the wheel loaders, while the ADTs are responsible for longer distance hauling from the raw coal stockyard or to dump discard from the processing plant,” explains Gert.

“The machines work very hard and have remained reliable throughout. We were the first mine in the country to take delivery of the WA480 machines and, with the exception of some small unforeseen breakages where replacement parts were not yet available, the machines have operated at an availability above 90% for more than 12 000 hours. The ADTs have operated flawlessly and, although servicing costs of the machines are relatively high, we maintain them in perfect condition according to the manufacturer’s specifications.”

Business decision Procurement manager, Martin Thorpe, says reliability and availability of the machines were the most important criteria when management made the decision to buy Komatsu equipment. “We made our decision based on a thorough investigation of the different machines available. We also conducted a fact finding exercise among management of other mines to determine which equipment would give us the best return on our investment. At the end of this long process we chose Komatsu.”

Dawid is able to keep a finger on the pulse of the mine’s equipment by making use of Komatsu’s sophisticated Komtrax remote fleet monitoring system. The GPS enabled technology provides critical information about equipment on site which can be remotely downloaded for Dawid to check on a number of parameters of the machines to ensure they are productive and running efficiently. The system is also used for proactive service and maintenance scheduling to keep the machines in tip-top shape.

“After initial teething problems our WA480s have proven themselves time and again, and in my opinion are currently the best wheel loaders available in the marketplace today. The HM400s are top quality, economical and very light on tyres. Overall our fleet is fast and efficient and meets our requirements,” Dawid concludes.

Komatsu’s mining machines play an all-important role in profitably processing coal from the relatively low-grade coal belt of Palesa Colliery in Mpumalanga.

Komatsu WA480 moving raw coal at Palesa Colliery

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Optimising after sales supportIn a globally competitive environment, where customers demand innovative products, competitive pricing, individualised support and high service levels, a strategic decision was made at Komatsu Southern Africa (KSAf) late last year to separate the Product Support and Reman functions of the organisation.

Johan du Toit, who has been with KSAf a little short of a year, has taken over the reins as general manager responsible for the Product Support and Service Division, while Brian Kivido, who previously managed both divisions, now focuses his attention on the Reman Division. This move has allowed each of these specialist areas to consider enhancements that will improve the company’s overall product support capacity.

Product SupportThe Product Support and Service Division consists of four departments, but the one receiving a significant amount of Johan’s attention right now is the Training Department. “Training is the cornerstone of the support function,” he explains. “Our ability to offer world-class support to our customers hinges largely on the capacity of our people and we need to empower them with the knowledge and skills to deliver.”

It is for this reason that an intensive programme is underway to revitalise the Training Department with the support of human resource and training specialists from both Johannesburg and Japan. “A master trainer from Japan will be reviewing the course outlines and training material to ensure that what we offer is on a par with other Komatsu training centres around the world,” elaborates Johan.

There are two main areas of training offered by the Product Support Division: operator training for new equipment being delivered to site; and technical training, which comprises product and hands-on training.

Operator trainingThe operators are the individuals who, on a daily basis, are entrusted with the use and management of equipment worth millions of Rands and it is for this reason that customers are calling for revised training that not only provides know-how to operate the equipment but includes basic technical information so that the operator can understand the technical consequences of decisions that he or she will make in the driver’s seat.

This obviously requires development of our in-house training capacity. Not only is the number of operator trainers being increased to meet the growing demand

but trainers are being sent to mother plants for specialist training which includes a general knowledge of the components in all Komatsu construction and small mining equipment. The training is based on a train-the-trainer approach so that there is a cross-pollination of learning amongst the trainers.

Technical trainingBoth product and hands-on training are offered to internal and external clients, and this can be done at the revamped training centre in Isando or on site if requested by a customer. “If a customer wants to maintain and service our Komatsu machines in-house, it is in our interest to ensure that they have a thorough technical understanding of the components and how they fit together mechanically,” says Johan.

Internally, on an annual basis, a technical needs analysis (TNA) is conducted worldwide to assess the knowledge of after sales staff and courses are then tailor-made to meet the specific requirements across the group and in different regions.

As with operator trainers, existing and newly appointed product and hands-on trainers are undergoing an intensive preparation programme to increase their knowledge of Komatsu products and the way the organisation does business – the KOMATSU Way.

It is important to ensure that the training efforts are supported by human resource processes which focus on the retention of talent. “There is a high demand for technical skills in the field and, in particular, we would like to ensure that we retain the trainers in whom we have invested and who have exposure specifically to Komatsu products,” adds Johan. “It is for this reason that I am working with my HR colleagues to put in place skills development plans and career paths so that we can retain valuable skills.”

Johan du Toit

Reman Centre

Optimising after sales support

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Remanufacturing, or reman, is an important part of after sales service that the company offers to its customers. The Reman centre can supply rebuilt components to keep a customer’s operations running at a fraction of the cost of brand new components and with limited downtime.

Recognising the value add of an effective and efficient Reman centre to the overall Komatsu brand, the board approved a Reman Kaizen (improvement) project for KSAf at the end of 2011, which includes a multi-million Rand upgrade of the facilities and tooling, as well as the establishment of an electro-mechanical shop.

The Komatsu group has a number of Reman facilities around the world, with two of the largest being KRI in Indonesia, which specialises in engines and transmissions, and KRCC in Chile, which focuses on electric drive truck components. KSAf collaborates with a number of these global facilities to procure components for customers rather than undertaking

the remanufacturing locally. A partnership such as the one with KRI to provide engines allows KSAf Reman to tap into these pockets of excellence and use the additional resources to focus on other challenges within the region.

The electro-mechanical shop in Isando will specialise in building wheel motors for AC drive trucks, a product which has seen an increase in demand because of the introduction of the more efficient AC drive technology.

As a child plant of Chile, the mother plant will assist with the design and building of the new facility and will certify the KSAf Reman centre to do the mechanical portion of the AC wheel motor rebuild.

Brian Kivido stands next to a refurbished wheel motor

“KSAf Reman will become a specialist in this area as there are not many other Reman facilities around the world that concentrate on wheel motors,” explains Brian Kivido, general manager of the Reman Division. “This will obviously also require specialist training and the first two technicians leave early in January to do training at the Chile mother plant.”

The improved technical capability, along with the new facilities, will enable the Reman team to rebuild 50 wheel motors at any one time.

The Kaizen project, which was supported by Reman experts from Japan, includes modifications to the existing workshop facilities which will improve efficiencies. The work has already begun and the plan is to open the revamped Reman centre in the third quarter of 2013.

“In the meantime we are making plans to minimise the impact of an intensive eight-month construction phase on our service delivery to customers,” assures Brian. “But it will be well worth it in the long run because we will be able to provide customers with a one-stop-shop remanufacturing service that meets the world class standards of quality and reliability on which the company prides itself.”

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Optimising after sales support

Fritz Weber (top) and Clement Mphehlo (bottom) show off some of the activities in the Reman centre

Excavators at the heart of Leeupoort

Komatsu excavators are at the heart of Leeupoort Colliery in Witbank where coal mining operations are showing good yields since the first cuts were made at the beginning of this year.

Despite difficult operating conditions the mining contractor, Burgh Plant Hire, is steaming ahead and meeting all the operational targets set out before mining operations began. The early success of the operation is due, in part, to the careful and accurate planning of the operation upfront as well as the rigid execution of the plans by the mining contractors.

At the coalface of the contracting operation is the company’s technical manager, Tommy Glover, who oversees the plant equipment and allocates resources to achieving production targets on a daily, weekly and monthly basis. He ascribes the high work rate to the flawless operation of his Komatsu excavators, which in turn keep the wheels of production in motion.

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New operationThe Leeupoort operation calls for three heavy excavators (two Komatsu PC850-8s and one PC800-7) to work in tandem with nine 40-ton Komatsu HM400-2 articulated dump trucks (ADTs) in teams of three trucks per excavator. With a required cycle time of less than three minutes for loading and a haul of well under two kilometres, the operation works smoothly as long as the excavators keep up.

“Our Komatsu excavators haven’t skipped a beat and, despite some tough soil conditions, they are fast enough to catch up any lost time as a result of excessive clay or the development of sinkholes. They keep the cycle running smoothly all day,” says Tommy.

He explains that excavators are the heart of the operation and directly influence the production. If, for example, production needs to be pushed up he has a choice of introducing an additional ADT, increasing the size of the truck or increasing the payload. While the excavators are at work they rely on wheel loaders and other equipment to work in support, either stockpiling material to be loaded in the case of wheel loaders or, for dozers, spreading material and covering up the strip once it has been mined.

The formidable Komatsu PC 850-8 excavator and HM400-2 ADT pairing working at Leeupoort Colliery in Witbank

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In the case of Leeupoort, the supporting equipment consists of two D375-5s and a new D375-6 Komatsu dozer which is already hard at work stockpiling the topsoil, soft and hard materials that were taken out prior to reaching the coal bed. Two Komatsu WA450 wheel loaders will soon join the fleet to assist in the shaping of the strips for safe and efficient mining to take place.

Extreme reliabilityIt is no coincidence that all the capital machines on the Leeupoort site are supplied by Komatsu. Tommy is a stickler for detail, and has all the facts and figures relating to plant equipment on this and other mining operations undertaken by Burgh Plant Hire at his fingertips. As a result he expects the same from operators, shift supervisors and even equipment salesmen.

He carefully analyses the operation of each machine in his fleet and can tell the amount of material moved by the machine, fuel consumed, service histories, as well as reliability issues and breakdowns that were experienced in the field. These records allow him to accurately allocate a cost for each machine per ton or cubic metre moved. “That is the nature of our business. We get paid to move a certain amount of material per month. If we don’t, it is our loss, if we do then we are all happy,” Tommy explains.

As a result of his careful record keeping he is convinced that Komatsu machines are the best option for opencast mining operations. This, he says, is due to their extreme reliability, durability and high performance while bearing a reasonable price tag. Exceptional back-up service received from Komatsu’s Witbank office, as well as availability of spares and parts, complement the machines’ performance and provide him with a good reason to standardise. He says he carefully compared his database of vital statistics of excavators, ADTs, wheel loaders and dozers before finalising the purchase of equipment for the mine.

Choosing right“I chose Komatsu excavators because of their high productivity rate. It has a good swing speed, superb hydraulics and is powerful enough to keep going all day without a problem. Fuel consumption of the new PC850-8s, in particular, is superb. As a price-driven operation, cost per ton moved is vitally important and the overall cost of buying and owning a Komatsu is unbelievable when purchase price, spares and economy are taken into consideration. But, the most important consideration is uptime: if the machine is down we lose money,” Tommy says.

He calculates potential lost revenue at R285 000 per day per excavator on this mine and says that’s why it is so important that back-up service is there when you need it. “That’s another reason why we chose to buy machines from Komatsu – great after sales service” adds Tommy.

The next choice was trucks to move materials on the site. This was limited to ADTs as the soft underfoot, rugged and slippery conditions were not suitable for rigid trucks. Tommy’s selection of the HM400-2 Komatsu ADT was based on its proven reliability and reputation for durability. With an expected operational lifespan of five to six years, the trucks will no doubt see out life of mine. “These trucks are indestructible and built to last. They have an exceptional resale value and in the event that they are not needed on one of our other sites when this mine closes, we will get a good trade-in for whatever our requirement might be then,” he adds.

Supporting actAs far as dozers are concerned he says he did not even need to look at his statistics because “it is a well known fact that the Komatsu D375 series is the best mining dozer ever built”.

“It is tough, durable, fuel efficient and operator friendly. What’s more it is by far the most powerful dozer in its class and can do the work of a much bigger dozer if need be. On our site each dozer will need to move about 150 000 cubic metres of material per month without skipping a beat – there is just no room for error with any other machine,” Tommy says.

While he has already placed his order for two wheel loaders he is continuously looking at the next phase of this and other operations under Burgh Plant Hire’s control, and drawing up requirements for plant and equipment.

The power of informationThe new Komatsu machines now give him yet another tool to measure productivity with the addition of Komtrax, Komatsu’s remote equipment and fleet monitoring system that provides critical information about equipment and production. For example, the system can show productive time of a machine versus idle time, working parameters, as well as efficiency.

“This adds another dimension to my management of a site. In the old days I would review the day’s production and make changes according to the tally man’s figures. With Komtrax I can see where the machines are, how hard they are working and how much we are moving at the click of a button. I have only just started using the system and already I am using the information to improve our operation,” Tommy says.

Tommy concludes that the combination of advanced technology, durable machines and efficient all-round service from Komatsu Witbank reinforces what his statistics already showed him – there are no better machines for opencast mining in South Africa.

Sishen trucks show real steel

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In a twist of fate, nature chose the harsh Northern Cape landscape as the perfect hiding place for a bounty of riches buried deep beneath the earth in the form of minerals, diamonds and metals. And, at Anglo American’s Kumba Iron Ore’s Sishen mine in the remote town of Kathu, man and machine have toiled for more than half a century to extract iron ore from one of the richest deposits mined by man.

For nearly two decades miners at Sishen have relied on a team of 44 giant Komatsu 730E trucks that endure in these conditions, reliably hauling millions of tons of iron ore for processing and export. Since their delivery in 1996 the first dump truck has recently notched up 100 000 hours of service. This is a remarkable feat considering that these trucks work 24 hours a day, 365 days a year with only short breaks in-between for services and maintenance.

But the truck’s longevity is no surprise to those who were part of the team involved in the initial procurement of the machines.

True workhorsesKomatsu Southern Africa’s Frikkie Booyens, who signed the initial deal and remains as the company’s current manager of mining business, explains that at the time the decision to buy Komatsu 730E trucks was a carefully considered one. Previous operators of the mine, Iscor, investigated trucks from six different manufacturers and stipulated a number of key requirements. Foremost of these was the requirement for a large truck with a payload exceeding 185-tons to quickly and effectively remove overburden of clay and calcrete, and then be able to handle the heavy iron ore which lies underneath.

“In the end the engineering experts decided that the 730E was ‘technically superior’ and the order was placed for 44 trucks. At the time they were considered to be giants with a payload of 192-tons. It was also the most technically advanced as this was the first time a truck of this size was produced to be totally airless with no pneumatics fitted.

Hardworking Komatsu iron ore truck reaches a major milestone of over 100 000 hours hauling heavy loads

“Until then air systems had been a major maintenance headache on all large dump trucks. In fact, the whole truck was produced to minimise maintenance and maximise uptime. Everything from a roll-in-roll-out power module to easy to reach service points and high reliability components combine to make the Komatsu 730E one of the best mining dump trucks of all times,” says Frikkie.

Long relationshipThe thorough investigation carried out all those years ago proved to be spot on and the flawless operation of the trucks has earned them a massive amount of respect from technical staff on the mine.

Frikkie takes great pride in being able to celebrate the trucks’ longevity after signing the deal so many years ago. The partnership with Sishen’s previous owners as well as the current owners, Anglo American’s Kumba Iron Ore, represents a relationship that goes beyond simple supply chain management.

Hugo Schreuder, engineering manager for mining at Sishen, agrees that the machines are well respected at the mine and adds that after 17 years the machines have become synonymous with the mine and remain highly productive. He attributes the feat to the high quality engineering of the machines and the ongoing collaboration between the mine’s technical team and Komatsu to keep the machines well maintained.

Local expertise“We are not your average customer. We have some of the best engineers and technical staff in the business and our relationship with Komatsu is a close partnership to optimise the vehicles for our purposes. In this way we are able to get the very best out of the machines that we operate,” Hugo adds.

In fact the mine’s engineers requested at least two major modifications on the 730E trucks that were eagerly adopted by Komatsu and designed into all future generations of the truck worldwide. These included the “Bigfoot” conversion which required higher profile tyres to enable the trucks to carry the required 192-ton payload when dealing with high density heavy loads such as iron ore. The other necessitated changing the camber of the front wheels which was designed to deflect under load. Anglo engineers found deflection was not an issue and the increased camber only contributed to tyre wear rather than improving the dynamics of the truck. This also led to a worldwide revision of the truck design.

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“Komatsu’s technical team supports us with any issue that arises on our fleet of trucks or where necessary to further improve productivity. For example, we analysed the oil of the trucks and found that the service interval could safely be moved from the standard 500 hour intervals to 1 000 hours without adversely affecting the longevity. Komatsu’s engineers checked our finding and approved the longer service intervals.

Sell themselves“The good relationship we enjoy with Komatsu is a long-standing and proud one in which both parties have benefited enormously from the other with technical know-how and an understanding of our unique operating requirements.”

Interestingly, Hugo explains that each generation of Komatsu dump truck has led to the mine buying the next since the original 150 ton Wabco Haulpak (predecessor to the Komatsu 730E to the next generation 860E-1KT and the current 960E-1KT series with its payload of 327 tons). Although the modern trucks tower over their predecessors they owe their existence on the mine to the reliability and productivity of the older generation of trucks.

“Nobody forced us to keep buying Komatsu, it is a business decision. The trucks meet our needs for cost effective, reliable and productive equipment with high availability and good life-cycle costs,” Hugo concludes.

Mining SishenSishen’s red coloured sand is due to its high iron content. Handful-for-handful it is two to three times heavier than loamy soil. The heavy weight of iron ore combined with the increasing depth of the pit necessitated the use of trolley assist. The trolley supply line is rated 1600 VDC, gradients are 10% effective and speed on the trolley is approximately 22km per hour. The main benefits of trolley assist is fuel saving and less time on grade resulting in increased component life expectancy and a reduction in the engine load factor.

Truck loading takes place with a variety of machines depending on the location of the dig, using either rope or hydraulic shovels or massive front-end loaders. It is easy to overload a truck with iron ore and just a single pass too many can result in the payload of the Komatsu 730E truck going well over 200 tons. Although precautions are taken to avoid this, it does happen from time to time, and for trucks to operate successfully in an iron ore mine they need to be able to stand up to these conditions.

Apart from the heavy loads the trucks are subject to high demands in terms of productivity and availability – there simply is no room for unreliable or unproductive machines on these sites. As a result of the rigid timetables and high productivity levels the miners extract more than 40 million tons of ore from Sishen per year. Thanks to Komatsu trucks, the ore is removed from the world’s biggest single pit iron ore mine and begins the long journey to the port of Saldanah where it is exported to steelmakers around the world.

Ultimate dozer

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These and other improvements brought about on the Komatsu D65EX-16 are in line with Komatsu’s ecot3 development strategy that aims at preserving the earth’s environment (ecology) and the customer’s productivity (economy) through the development and use of advanced technology. The machines meet EPA Tier 3, EU Stage 3 and Japan’s off-highway special automobile clean air act, which all require substantial reductions in nitrogen oxide (NOx), particulate matter and hydrocarbons (HC).

Komatsu once again adopted an engineered approach to meet these stringent requirements. Rather than sacrificing power or complicating its components, Komatsu chose to optimise engine, hydraulic and electronic operations on board the new machines. Using ecot3 principals the Komatsu machines are able to meet emission requirements without the addition of complicated emission reduction devices that can potentially compromise efficiency, durability or productivity.

Ton-for-ton moved, the new Komatsu D65EX-16 dozer also works more efficiently. Thanks to a more powerful 8.27-litre engine producing 153kW, the 21 280 kg dozer (as equipped with a semi-U tilt dozer blade and multi-shank ripper) can compete with far heavier machines in terms of actual earthmoving ability. The new machine is built even tougher than its predecessor with heavy castings used for extended chassis life and high strength materials used throughout its frame, engine and body construction. This makes it an exceptional all-rounder suitable for applications from mining to construction, landscaping and civil works.

Engineered equipmentTypical of the Japanese manufacturer, it has not changed the design for change-sake, but used feedback from customers in South Africa and other parts of the world to improve and enhance the operation, reliability and longevity of the machine. Despite the new design features Komatsu engineers have still ensured, where possible, that interchangeability of parts remains possible to ensure operators with older Komatsu machines can maintain simplified spares holdings.

Komatsu’s introduction of the new D65EX-16 crawler dozer represents a shift in dozing technology from brute strength to a poised machine that turns on the power only when it needs it and moves more earth with less effort in less time. This ability is made possible through

clever mechanical designs and new technologies that

radically improve dozing performance, reduce fuel consumption and, as a result, produce less carbon emissions.

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Dependable machineTotal cost of ownership and economy is further enhanced through the use of a four-speed automatic transmission with lock-up torque converter for lower fuel consumption. Different working modes are easily selected by the operator depending on the terrain or work requirement and this enables the machine to select the optimal gear for the kind of work being performed.

Serviceability of the Komatsu D65EX-16 is ideal for harsh African conditions with a big-screen LCD display allowing troubleshooting from inside the cab and easy access to the engine through wide-opening gull wing engine cover doors. One side start-up checking and easy reach maintenance points make the machine easy to maintain in the field. Additional electronic sensors guide operators to top-up fluid levels and filters on site.

The new dozer is equipped with the latest Komtrax technology which sends vital information about the machine remotely to a secure website for monitoring. Information includes the service meter hours, equipment location, cautions, load ratios, fuel consumption and maintenance alerts, amongst others. The Komtrax fleet monitoring system enables increased machine availability, reduces the risk of theft, allows for remote diagnosis by the equipment operator/owner and provides valuable information that can help drive higher levels of efficiency and productivity.

Komatsu machines are renowned for their durability and reliability and previous models of the D65 were no exception. Technical staff at Komatsu, however, decided to push the envelope a little further again with enhancements to increase durability and reliability of these machines. Large cast parts are used for the main frame and track frame to increase service life while a host of design changes enable the machine to run for extended periods in even the harshest operating conditions.

Improved comfort Operator comfort is an important aspect of the D65EX-16. Everything is designed for simple control and ease of use. The easy-to-use Palm Command Control System (PCCS) allows the operator quick and effective control of the machine.

Comfort in the large cab is enhanced by a low noise environment while the air conditioned cab provides a comfortable working environment. The high rigid cab allows maximum visibility and control, while the large LCD display contributes to the operator’s awareness of the machine’s position and performance.

Water for the nation

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Its machines are put to work in a number of roles from new-build projects for dams, canals, pump stations and pipelines to rehabilitating and maintaining existing infrastructure. The performance and reliability of these machines under all working conditions are critical to achieving the Department’s mandate and, as a result, careful fleet management is required.

The management responsibility for this fleet resides with the Chief Directorate: Construction Management and in particular with chief engineer, John Baker, who oversees all aspects of equipment operation carried out by the construction division from acquisition to disposal. His experience spans many years and his knowledge of earthmoving equipment is comprehensive.

Hard workersAmong the top performing machines in his fleet, John includes Komatsu excavators and dozers as being industry benchmarks for performance, durability and reliability. When measuring overall quality of the machines in his fleet, he has high praise for all the Komatsu machines.

With a host of new projects happening around the country, he says the Komatsu machines continue to be incorporated into the DWA’s yellow fleet. This is thanks to competitive pricing of the machines, as well as high levels of after sales service across the board by Komatsu Southern Africa and the ready availability of parts and spares.

John says, as the number of Komatsu machines increases along the country’s waterways and dams, they continue to earn a reputation for quality: “On the DWA sites where they operate, the machines are invariably known to have an above average useful life compared to their peers.”

Industry standardThe excavators and dozers in particular have excelled in the DWA fleet. Their robustness also makes them ideal for the varied work that is expected of them. Unlike mining operations or repetitive construction contracts, the DWA machines are often employed to do varied tasks and the adaptability of the Komatsu machines means that they are able to undertake most tasks required of them.

With a fleet of over 1800 yellow machines, the construction division of the Department of Water Affairs (DWA) plays a pivotal role in ensuring a continuous supply of water for our nation.

Department of Water Affairs chief engineer, John Baker and Komatsu’s Lourens du Plessis with the Department of Water Affairs’ D85EX dozers

A good example is the fleet of machines that was assigned to construct the massive De Hoop dam in Limpopo. Among them are the workhorse Komatsu PC200-7 (20 ton) and PC450LC (45 ton) excavators and D65E dozers that have performed flawlessly throughout the duration of the project.

With the construction phase about to be completed these machines still have a long and useful lifespan and, as a result, will be deployed on other assignments across the country. These tasks will require versatility as the machines will be deployed on varied jobs from foundation excavations and demolitions to canal building, trenching or any other work that is required.

Government policyJohn says that due to the very necessary rigorous procurement policies, the Department has to tender for all its equipment requirements. “That means that machines are selected from the most suitable bidder using a points system that considers price as well as a number of other criteria. As a result we have a mixed fleet from different suppliers and comparisons can easily be drawn.”

He says that in recent years Komatsu machines have become more keenly priced and as a result tenders submitted by companies offering Komatsu machines have enjoyed some success. Another benefit of dealing with a leading international company is that special requirements can be fulfilled and, where necessary, specialised machines can be brought in from its global network.

Machines like the impressive WD500-3 wheeled dozer, which is used in the construction of pipelines in the Levubu district of Limpopo, are quite unusual. Thanks to its wheeled design and specialised transmission the dozer is able to move quickly along the construction area, while maintaining similar dozing abilities to its tracked cousins. On the other end of the scale, the wide range of machines available also means the Department has a large number of standard machines such as graders, TLBs and skidsteers on sites around the country.

Fleet managementProductivity on site is a key requirement of the machines. John adds that Komatsu’s remote equipment and fleet monitoring system, Komtrax, provides critical productivity information on some sites, ensuring better management of machines. “We recently began using the system on a number of our machines and initial feedback confirms that it is proving to be a useful tool for our project managers.

“We can’t always choose which machines the Department buys, but when we deal with Komatsu we find the machines to be among the best. In addition we find the staff to be knowledgeable and above all they are conscientious. They do what they say and they back their product,” John says in conclusion.

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“We find the staff to be knowledgeable and above all they are conscientious. They do what they say and they back their product.”

Photo courtesy of : Department of Water Affairs: Construction West: De Hoop Dam

With over 90 years’ experience in providing different types of equipment to a variety of industries, Komatsu has become accustomed to calls for modifications that will make its machines suitable for specialised functions.

Kynos Special Vehicles, a company specialising in recovery vehicles, approached Komatsu to collaborate in the provision of a custom-built vehicle required by Transet, the parastatal responsible for the operation, maintenance and management of the country’s railway logistics network.

Transnet provides various services to move both freight and passengers around South Africa. On the unfortunate occasion when there is a derailment on the railway lines, the company requires robust equipment with good stability to operate in flat or mountainous terrain, and the capacity to lift and move heavy locomotives and carriages.

The public tender document issued by Transnet specified the requirements as a vehicle that can operate as a forklift but also with good traction and winching capacity. There is no single ready-made machine that can offer all these specifications.

After some investigation of what is available on the market, Kynos S.V. settled on the Komatsu D275AX-5EO as the primary drive unit which has a track system and a winch but does not have the forklift function. “It is here that the two companies joined forces to deliver a unique and specialised vehicle that would meet Transnet’s needs,” said Kynos MD, Johan Botha.

Kynos added to the basic Komatsu D275AX dozer a forklift system which can lift 28 tons with 3m forks. The forks can be widened from 1.5m to 3m with a hydraulic fork spreader which is “quick hitch” mounted for ease of transport.

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The hydraulic operated winch has a pulling force of 55 tons with a 32mm diameter IWRC wire rope which stretches to 60m in length.The hydraulic system is a two stage system with four cylinders working through two flow devices to ensure equal flow and pressure.

The complete dozer can be lowered for transport to a height of 2 900mm from the original height of 4 000mm.

Komatsu’s sales representative, Kevin de Wet, who negotiated with Kynos S.V. on the development of this equipment, says it is ironic that he started with Komatsu (then known as Sigma Power) in 1981 in the forklift division and, with his imminent retirement, should finish off at Komatsu with a D275AX-5EO that sports a forklift. “Credit must go to Kynos for their innovative thinking,” adds Kevin.

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The Relay for Life is a 12-hour event that runs through the night and is divided into three parts: Celebration, Remembrance and Fighting Back.

The evening began with a celebratory lap of honour for cancer survivors and caregivers, and this was followed by an emotional candle lighting ceremony to remember those who have lost the battle against cancer or who are still battling the disease.

The third part of the event captured various commitments from people in the community to fighting and preventing cancer. The commitments, which included things like quitting smoking and volunteering time as a caregiver, were written on a wooden door in line with the campaign slogan: “fighting back is the door to a cancer free community”. This door will feature in the Care House that is being established in Kathu as a reminder to the community of their public pledges to defeat cancer, which is still one of the leading causes of mortality in the country.

Relay for LifeEarly in November, the fourth regional annual CANSA Relay for Life was held at the rugby stadium in Kathu, the iron ore capital of the Northern Cape. For the second year, Komatsu employees and family members supported and participated in the event organised by Kumba Iron Ore’s Sishen mine, despite the inclement weather.

Twenty-eight teams entered the relay and 80 people saw the night through by walking the track, despite the weather and fatigue. There was lots of national and local entertainment and a variety of food on offer at the Relay Event which raised in excess of R200 000, the largest so far in the history of the Kathu event.

Besides entering a team in the relay, the keen Komatsu employees braaied three sheep and sold the meat along with 28kg of potato salad which had been made by the ladies in the team. From the proceeds of their efforts they were able to donate R6 000 to CANSA.

Cindy Nordman, a Komatsu employee and safety officer at Sishen Mine, summed up the spirit of the event perfectly: “What made this year special was that, despite the rain, the event went ahead. This is similar to the fight against cancer. You have plans for your life but cancer can easily disrupt your plans and goals. However, as this year’s event proved, cancer can be beaten and the fight can be fought against all odds.”

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It was on this basis that Komatsu’s West Coast area manager, Spencer Williams, motivated for the company, through its Bellville branch, to support the GlenBridge Special School and Resource Centre in Cape Town which supports around 100 learners - between the ages of 6 and 18 years - with special learning needs.

The school started in 1975 as a privately owned and managed facility but was taken over by the Western Cape Department of Education in 1981. It was the first school of its kind to open its doors to mentally handicapped children of all races in 1992, and many of the children who attend the school today still come from disadvantaged backgrounds.

Developing and nurturing each intellectually-challenged child to reach his or her full potential requires specialised education programmes, proper equipment and trained staff. Funding remains an ongoing challenge for the school. Komatsu has committed to an annual donation of R40 000 to contribute towards the costs of nutritional school lunches for the children and specialised sporting and educational equipment.

In a letter of thanks to Komatsu the school noted: “Working with these children is indeed a privilege and our dream at GlenBridge is ... for these treasures to be afforded the levels of excellence that they, as compromised and vulnerable individuals, so sorely deserve.”

“We are proud to be associated with this school which is doing such excellent work in the communities where many of our employees live,” says Spencer.

Unearthing treasures in our communitiesA commitment from the private sector to support upliftment in local communities is not only a corporate responsibility but is critical for the social and economic development of the country.

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The learners at GlenBridge showing off their Komatsu-sponsored kit

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Komatsu Southern Africa (Pty) Ltd, cnr Diesel and Isando Roads, Isando. Tel: 011 923 1000 | Fax: 011 923 1111Customer Care Line: 0860 566 2878

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