THE INTRODUCTION OF MULTI-TASKING THE UNDERGROUND OPERATIONS AT KRIEL COLLIERY'

J.D. Thornton

KRIEL COLLIERY

1.

2 .

3.

4 .

5.

6 .

THE INTRODUCTION OF MULTI-TASKING TO THE

UNDERGROUND OPERATIONS AT KRIEL COLLIERY

INTRODUCTION

R A LAYBOURNE J D THORNTON

A DE JAGER

A DRILL AND BLAST SECTION

OBJECTIVES

IMPLEMEN'l'ATION

4.1 Proposed Structures 4.1.1 Production Section 4.1.2 Outbye Areas

4.2 Strategy 4.3 Initial Briefing 4.4 Follow-Up Training

RESULTS ACHEIVED

5.1 Multi-Skilled Operations 5.2 Bonus Scheme 5.3 Primer Magazine 5.4 Section Equipment Trains 5.5 Conveyor Transfers

CONCLUSIONS

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1. INTRODUCTION

Kriel Colliery is situated in the Eastern Transvaal, 120km East of Johannesburg and SOkm South West of Witbank. The colliery was established in 1976 to produce 8, S million tons of coal per annum all of which is supplied to the 3000 MW Kriel Power Station.

To meet this requirement, coal is produced from both underground and opencast operations of which the underground operation has a capacity to produce 4 f 008 million tons using a combination of conventional drill and blast mining and continuous mining techniques.

Mining is carried out approximately 70m from Srn in thickness of which underground operation.

in the No. 4 coal seam which is surface The seam averages some the lower 3,8m is extracted in the

The Kriel Colliery underground operation has been one of the leaders in coal production using drill and blast mining methods. This has been primarily due to the good mining conditions and high mining tempos.

During the late 1980's there was a drive to increase productivity in the South African coal industry in order to remain competitive with world markets, particularly Australia and the United States.

In order to achieve this, several mines introduced the mul ti-task concept in order to reduce complements and improve productivity. The introduction of longwall and shortwall operations at New Denmark Colliery lent itself to multi-tasking and New Denmark pioneered the concept in the Amcoal Group.

In 1990, Kriel Power Station forecast a reduction in coal requirements for the period 1991 - 1993, due to technical problems at the power station and as a result of a nation wide surplus of power. This situation provided an excellent opportunity to introduce multi-tasked operations at Kriel Colliery and co-incided with the planned relocation of the underground operations to the new North West Shaft complex.

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2. A DRILL AND BLAST SECTION

2.1 Conventional Section Layout

The conventional drill and blast mining method used at Kriel is a cyclic operation conforming to the bord and pillar design. There are five operations which make up the production cycle, these are (1) roof support (2) coal slot cutting (3) drilling of explosive holes (4) explosive charging and blasting and (5) coal loading. Mining takes place in a section consisting of up to 15 roadways and each operation takes place in a roadway following in sequence. Each completed cycle will produce 70 tons of coal and up to 30 cycles can be completed in a shift.

A typical section will have its own section conveyor with feeder breaker, its own independent intake and return airways for ventilation and have its ancilliary equipment arranged in trains. Figure 1 shows a plan of a single header section layout.

2.2 The Existing Structure

The inbye section structures consisted of 3 senior skilled employees (Artisan/Miner), 13 skilled operators and 9 skilled general employees (total 25) with job groups ranging from 7 to 2. The outbye section structure consisted of 12 skilled employees from bricklayers to Belt Sweepers with job groups ranging from 6 to 2, see Table 1.

All employees had specific job descriptions and were designated to only one type of task. They were generally reluctant to do any other tasks outside of their job description. Maintenance and repairs to machines were handled by the Engineering Department with little or no involvement by the Mining Department.

3 . OBJECTIVES

Kriel Colliery's primary objective was to introduce multi­tasked operations to the conventional production units in order to improve productivity and to increase the level of skills. In order to achieve this it was necessary to change certain entrenched practices. During the re­organisation a number of other objectives had to be achieved to meet this goal.

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1. Change the existing daily task bonus scheme to a monthly paid tonnage related section bonus scheme.

2. Establish a culture amongst the operators to assist with engineering functions such as machine lubrication, machine repairs and machine maintenance, so that engineering aides and helpers would be +emoved from the section.

3. Removal of the made up 'primer' magazine thereby enabling the blasting assistants to remain in the face area to assist with other operations.

4. Conversion of the section ancillary equipment to a , train' concept f thereby decreasing the work load required during belt extensions.

5. Conversion of the conveyor coal transfer points at the head and tail section to improve spillage.

6. Implementation of section belt automation to remove the belt operator.

4 . IMPLEMENTATION

4.1 Proposed Structure

4.1.1 Production Sections

The proposed structure allowed several operators to be upgraded and required that they obtain the necessary licences to qualify. The new structure was 9 job group 7 multi-skilled operators and 7 job group 5, multi-skilled operators requiring the following licences.

MULTI-S~ILLED OPERATOR MULTI-SKILLED OPERATOR

JQb Group 7 Job Group 5

Minimum 3 machine licences Minimum 1 machine licence Barring Barring Blasting Blasting Feeder Breaker Feeder Breaker Machine Lubrication Machine Lubrication

4.1.2

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With this increase in the overall requirement the training of Operators became a significant undertaking and additional instructors were used full time in the sections on both shifts.

The original job description had to be re­written to embrace the change in emphasis. Examples of an old style job description and a new style of job definition are given in Appendices I and 11 respectively.

Outbye Areas

Once success had been achieved in the production sections multi-tasking was extended to the outbye general crews.

The outbye crews consisted of mainly general workers designated to do specific tasks. The re-organised structure allowed these employees to do a wider range of tasks as well as operate certain applicable machines.

The multi-tasked operators are required to have a minimum of one machine licence and to be trained in the following tasks :

OUTBYE MULTI-TASK

Building of brick walls Pumping Belt extensions Bit sharpening Shaft guard General tasks

4.2 Strategy

The re-organisation was designed in such a way that it offered a number of advantages to the majority of employees in the form of an increased bonus scheme and upgrading. The excess labour resulting from this process was generally accounted for by natural wastage over a period of two years.

It was decided from the outset, that it would be better to select an existing team for re-organisation and not to form a team using selected operators from across the mine. It was felt that an existing positive team stood the greatest chance of success as they already had team cohesiveness.

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4.3 Initial Briefing

The first team was selected and briefed on the proposed re-organisation structures, new revised bonus scheme and job re-grading. During this briefing session all mis-understandings and problems were resolved. The excess labour was then removed from the team and were assigned other duties.

4.4 Follow-Up Training

Approximately 3 weeks after conversion, each team was taken for follow-up training sessions, lasting a full day, at a venue off the mine. The main objective was to resolve any problems that may have occurred since the re-organisation and to train operators, through group discussion, in the following :

1. Lubrication points on machines 2. Industrial relations issues 3. Productive mining procedures 4. Good face preparation 5. Leave planning

In addition to the formal discussions and training, emphasis was also placed on team building, motivation and group dynamics.

5. RESULTS ACHIEVED

5.1 Multi-Skilled Operations

All production sections and outbye areas are now totally multi~tasked which resulted in the following improvements in productivity using a common production base.

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TOTAL UNDERGROUND MINE

DESCRIPTION OLD PRESENT % EXISTING RE- CHANGE STRUCTURE ORGANISED

F1990 STRUCTURE F1993

Production Ton/Month 300 000 300 000 -

Total Labour 679 402 -40%

Tons/Man/Year 5 302 8 955 +68%

5.2 Bonus Scheme

The main impact of the change to the bonus scheme has been an increase in the average blasted face factor of 73 tons/face to 79 tons/face (+8%) without any increased drive by supervisors. In addition, section potentials have generally increased on average as teams now leave more coal for the opposite shift, since they share a common monthly production bonus.

5.3 Primer Magazine

Removal of the primer magazine has improved the security and safety of explosives in the section and allowed the operator to be more directly involved with other operations.

5.4 S~ction Equipment Trains

The section equipment consists of a miner's box, material skid, artisan's tool box, section switchgear, cable skid, section transformer, lubrication car and a spares box, all of which are connected together to form two trains.

Each train is pulled forward during belt extension moves and has its own lighting system. This has reduced the manpower requirements and has saved time during moves.

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5.5 Conveyor Transfers

All conveyors now stop/start automatically and transfer points have modified to prevent spillage. They are now no longer manned.

6. CONCLUSION

the underground mine has During the past three years experienced considerable rationalisation whilst, at the operations from the A1 Adit shaft Shaft mining area.

re-organisation and same time, re-locating

complex to the North West

The multi-tasked philosophy is now firmly entrenched into all operations, both at the skilled operator level and at the senior skilled miner and artisan level. In most cases all operators are trained to operate more than one machine, licensed to conduct charging and blasting operations and to effectively lubricate the machine they operate. They are also now actively involved in the machine maintenance program and assist the artisan with breakdown repairs. An agreement was reached between the Mine Workers Union and Arncoal in March 1993 which allows section miners to be involved in multi-tasking and in return their bonus levels were increased. The section miner's duties now include minor repairs to machines and replacement of minor components where there is no high level of expertise required. Negotiations are still in progress with the engineering unions to pave the way for their total involvement in multi-tasking.

The objectives that were set prior to the re-organisation have been achieved and production levels from each of the operating sections are trending toward levels previously achieved using the double header layout. Targeted production levels of 50 000 tons per month are regularly met with some sections achieving in excess of 60 000 tons per month. Productivity has improved by some 40% as a result of multi-tasking.

At present more emphasis is being placed on improving the skills of the operators and miners in maintenance and lubrication of machine and general engineering knowledge of the machinery used.

APPENDIX 1

OLD STYLE JOB DESCRIPTION

JOB TITLE DRIVER - NO.2 ELECTRIC DRILL

SECTION UNDERGROUND - NO.4 SEAM DEPARTMENT MINING

COMPANY KRIEL COLLIERY

NO OF INCIMBENTS 10 DATE : 15 JULY 1993

PURPOSE OF JOB ASSISTS IN THE OPERATION OF THE ELECTRIC DRILL, HOLDS DRILL ROD STEADY WHEN COLLARING HOLES

1. Assists the No. 1 drill driver to visually and manually examine electric drill and cable by feeling along it with hand for damage or cuts. Reports any defect found to the No.1 drill driver. Once per shift about 20 minutes.

2. Examines drill auger visually for straightness and wear and drill pushing stick and duff trap for damage. Reports any defect to the gang leader of the section. About 5 minutes.

3. Places drill bit into the end of the drill auger. Inserts a small pin into a hole in the end of the auger to secure the drill bit. Places the shank of the auger into the chuck of the drill, according to the oral directions given to him by the No.1 drill driver. Holds it whilst the No.1 drill driver starts the drill rotating and drills into the coal for about six centimetres. Releases the drill auger and assists the No.1 drill driver to lift and position the drilling machine into position for the correct position for direction. Pushes the drill until all the auger has entered the face (2,4m). Grasps the auger with both hands and withdraws it from the hole. (When the No.1 drill driver has taken the drilling machine off the end of the drill auger). Takes the old drill bit out of the auger end and replaces it when it becomes blunt with a new one by hand. Repeats the same procedure for the next hole. About 120 times per shift, about 2 minutes per hole, about 15 minutes/face.

4. Carries his drill auger, duff catcher and drill flusher by hand to the next face to be drilled (about 50 metres). Walks behind No. 1 driver and pulls the slack cable and hangs cable up on hooks suspended from the roof, by hand. About 18 times per shift, about 5 minutes per face and 18 faces per shift.

5. Carries the drill auger, drill pusher and duff catcher to the main electrical switchgear at end of shift, walks behind the No.1 drill driver and by hand unhooks the trailing cable. Assists the No.1 electrical drill driver to putt out the trailing cable and coil it neatly by hand at main electrical switchgear. Once per shift about 20 minutes.

APPENDIX 2

OPERATION AREA

Underground Production

NEW STYLE JOB DEFINITION

GROUP

7

JOB DEFINITION

*To be in possession of valid mine licenses to operate a minimum of three machines applic­able to the work environment.

* In addition to operating the mine equipment for which he is licensed, and operations for which he is certificated the incumbent is expected to carry out any of the tasks associated with the operational area (subject to him being competent and adequately trained) providing that such tasks are not covered by the "Mines and Works Act and Regulations" : , nor current agreements reached with the Federation of Mining Unions.

REQUIREMENT

*Be literate (As in mine/divisional requirements)

*Valid Red Ticket

*Valid First Aid Certificate

*Mine licences to operate a minimum of 3 machines -e.g. - loaders - continuous

miners - road headers - shuttle cars - drill rigs - coal cutters - roof bolters - shearers - continuous

haulages - L.H.D.s - tractors - material/equip-

ment transport vehicles

- personnel transport vehicles

*Colliery's Test Certificates for:

e.g. - gas testing - barring down - charging up &

blasting - equipment/

vehicle lubrication

- longwall/short­wall hydraulic chock

- belt extension (including belt lacings and the installation of structures)

- belt feeders / breakers

- mobile rock/dyke scaler