March 26, 2004 WRMMA Meeting Minutes Elko, Nevada
Stockmans Hotel & Casino - Upstairs
7:00a.m. to 7:30a.m. Sign in
Dues $30.00 per person $100.00 for 4 persons or more from one site
WELCOME AND INTRODUCTION
7:30a.m. to 9:15a.m. General Business Report Outs
In Attendance
Mitch presented the objectives of the meeting, as well as, ground rules, agenda, and core guiding principles. Mitch noted that in the agenda there will be a section that will involve detailed supplier participation and that the presentations were not to be a "sales pitch". He discussed that it was important that we get good feedback as to whether or not this type of interaction should continue.
Placer Dome Cortez All of Placer Domes mines sent representative to Chile to discuss equipment, challenges and best practices and felt that it was valuable to connect and understand that other sites are experiencing the similar things. The company is communicating monthly globally. Benchmarking between properties and combined reporting is being tested. Measuring standard parameters to understand business as a whole and still independently. The hope is to identify problem areas for increased focus and assistance to bring the site or area back into good order. The member commented that language is a barrier. Safety best practice implemented a weekly safety audit that covers different areas .shops, crushers, pit, mill, etc. They police themselves and improve safety items before someone gets hurt or regulatory agencies impose citations or fines. It is a proactive approach to accident and incident prevention. Carlos mentioned that it was a real eye-opener to see how other parts of the same mine site do things. Some things are acceptable in one area but not in others. It gives a real objective view of different areas. It is done by an individual mostly, but can invite others to participate. It is a fairly new practice and the results are not in yet.
A member stated that Newmont is doing something very similar, but it involved personnel from different areas going into a different area for four months. Another member stated that the maintenance best practice is to enhance the backlog execution by involving supervisors and better inclusion into the plans. They also started involving operations for input prior to planned work.
Carlos asked the group for how they do this involvement and specifically how pre-PM inspections are scheduled and performed. A member discussed that the pre-PMs at Newmont East are scheduled two days in advance and allows them to get a better plan together as well as parts prior to the unit coming in for PM. A member stated that Twin Creeks Mine does a similar process except the inspections are done five days in advance of the PMs and that two technicians are assigned full time to pre-PM inspections. These two technicians will also ride along with the operator to find out specific problems that will need to be address on the PM. If a safety item is found on a pre-PM inspection these two technicians take care of the problem or down the equipment for unplanned work. The only time that pressures are taken is if there is indication of a problem. Another member is a firm believer in this process and was not warm to the idea originally. A Co-Chairman commented that the feel good side of this equation with the operations personnel is invaluable. If a problem is not taken care of at the time of PM, then it is documented as to why the work was not done and the operations personnel can go into the computer and see what the situation was. The operations representative gave a good description of the operations standpoint on this process and states that training for the supervisors and operators are needed in order for them to go in the system and see the text. The operations representative states that this process keeps operators reporting problems as opposed to them just clamming up and getting tired of reporting problems that do not ever get remedied. Another member talked about backlog and how it is monitored and uncompleted backlog deserves an explanation and communication back to the operator. Lone Tree used to leave a copy of the completed backlog or plan in the vehicle for communication to operations as to what was actually completed. The member states that they do not do this anymore and have went to the pre-PM process similar to what Twin Creeks is using. The member also stated that they are trying to close out the entire backlog if possible. Another member stated that Twin Creeks uses parts coordinators to run parts back and forth to the inspection technician.
A member says that Cortez is using a pre-shift conference call to enhance turnover and communication between operations and maintenance. They are also using LED Strobe lights instead of the conventional strobe lights. The LED strobes are much more visible and use them to help mechanics locate drills to work on etc. The new models will have twelve different strobe modes and a low battery indicating mode. A safety best practice that needs to be developed for areas where tire deflation and air arcing are performed. Cortez uses magnetic signs to put up in the areas of loud noises. They are looking into sound deadening curtains. They have had fuel filter issues for about four years and can not see anything in the filters as far as contamination. They spin on new filters and the problem is cured for a while. The problem is when the temperature is falling and when it gets to about 22 degrees the problem is the worst. Conversely, when the temp gets to zero there are no problems. Then, when the temperature hits the same 22 degree temperature range filters start plugging up again. They are working with two different labs to get to the bottom of the problem. They have tried many changes and have not had any appreciable success. They had a rash of fuel pump failures that were unexplainable and remain a mystery. A member asked how the other sites recorded fueling information. Most sites use Modular Mining Automated features. Others enter by hand and deal with large variances and resulting allocations.
Lone Tree Mine A member states that they are deep into the LED lighting conversions. He also talked about having one 16G grader equipped with graphite and auto lube system. Twin Creeks has one grader equipped also. Another member seems to remember that the payback was about 11 months for the LED light conversion and saves about $10,000 per year in parts and labor. Another member states that Placer Dome uses HID hi intensity "flood configuration" lights for the high beam application on the trucks. He states that they are expensive and just under $500 each. Another member stated that they did not get good acceptance in the high beam application; especially if an operator doesnt dim their lights or something. He stated that the latest unsuccessful light experiments were berm lights, and fog lights at Newmont East operations.
Carlin North Area a member states that they are having low hour 994 loader transmission failures. He asked specifically if anyone else was having problems and was it related to the new clutch disc material that CAT switched to recently. He states that a safety best practice is to not let operators drive the mining equipment on the aprons or in the bays due to congestions. They also modified the grader mounting location to make it safer for the operators. They also installed grab iron type handrails for safer oil level checking for the lube technicians. A member states that anytime someone is on the chain case that they have a grab iron within reach.
Carlin A member asked about who is using the Z-Bore valve stem system. They are using super large bore valve stem systems. The flow diameter is .44" with 240 cfm flow for the super large bore and .56" for the Z-Bore with flow at 370 cfm. A member states that price difference is negligible and both systems use the same inflating tool. A member states that Placer Dome has been using this for about four years and are Rimex products. A member states that they use Tire Life and had some problems with o-ring degradation using Rim XL. Ellis states the LTUG / SMART meeting is in May or June and will be at Fort McMurray / Tar Sands in Canada. This member will be converting as the tires come around for changes or repairs. Tire deflating exhausters are being used at most sites. Placer Domes tire exhauster design is located on the web site www.master-mechanics.org the member stated that pressure vessels were a big issue in Carlin at the moment and that they were out of compliance on some units. Placer Dome had a problem with inspectors and finally was able to confine the inspections to stationary installation and left the mobile units out of the scope. There is a minimum size of five cubic feet that these inspections apply. Newmont uses a third party to do the inspections and provide the information to the insurance underwriters. A member states that there is way too many regulatory agencies involved and it is very time consuming and interruptive to the business at hand. Another member states that they have a 20 mile haul that is a big challenge and has amassed a great knowledge base related to tire temp monitoring and long haul tire related issues. They are drilling and probing to get the readings from the tires. The process is labor intensive but the best way to get accurate information. A Co-Chairman asked if anyone was using an onboard monitoring system. The group indicated that the on board systems to date have much to be desired. This member feels that the expense of an onboard system is not going to be of great value due to the fact that the tireman will still be doing hand checks etc. A member talked about the PASS safety system and its progress is at about a 60 -90% participation level. It asks in a proactive way ..what are you going to do safely today or what did you do safely yesterday, and who did you acknowledge yesterday for doing something safely .etc. a member and another member state that their incident rate is definitely lower this year as a result.
Carlin North Area A member states that using old pressure vessels for other applications is not a good thing and can be an issue if they are pressured up for any reason in the different application. Fabrication of coolant buggy, for example. He also states that they have went to a back up alarm that was originally used at Lone Tree and is less expensive and the same brand as the one in the CAT box. They also installed a pilot reversing mechanism to kick the hoist cylinders out just before dead heading in the extended position. He states that hoist cylinders last significantly longer.
Carlin A member discussed the new global maintenance manual that has been developed and is being implemented soon. It is very in-depth and detailed and can be used as a template for starting up new mines and maintenance program development. This implementation is a pilot project in Nevada Newmont operations. He showed a copy of the turnover / shift communication sheet in use at Carlin operations. He states that the sheet is updated just minutes before the combined function meeting. Newmont has also started a global department sharing system that is a "think tank" and will be used as a standard tool. The CAT Mine Star system has been purchased and is currently being installed in all Nevada operations. The system will be tied into VIMS and the TPMS systems for data collection and monitoring. It is a GPS system and will require a "dispatcher". The monitoring Mine Star system capability is very diverse and transmits live data. The system is very customized and all the "questions and answers" are not totally clear at this point. Cost comparisons between Modular Mining Dispatch and Mine Star are equivalent in general.
Newmont Western Nevada A member states that he has a safety meeting every shift. He feels that talking about safety every morning before the technicians go to work has been beneficial. They have acquired a Meta-Lax system and are providing training to the welding technicians. He states that the tool is just an enhancement to the standard welding procedures and does not replace the need to pre or post heat for example. One comment from a welder that was welding in an overhead position was "it seemed like the weld was just sucked into the material". The system is used by many OEMs and the welders really like the increased density of the welds and claim that porosity is much less an issue. The member states the tool is a thermal stress reliever and expects repairs to last much longer before seeing cracks in the same areas return. The system is sold and serviced by Bonel only. Best practice trying a new filter system that uses spin on filters. The system is being used on a 994 hydraulic system to reduce particle counts. The filters are 3 micron rated and much less problematic than the Harvard style canister filter system. Twin Creeks has moved case drain access to one convenient location on the machine and place them on a manifold. Another member states that last year Twin Creeks started a multifunction safety inspection team that go to different areas each day and inspect the area for deficiencies. The other safety enhancement was to discuss safety issues right after the morning meeting among the managers present. They also go on safety walks each morning and talk to the hourly employees and inspect the areas. Twin Creeks installed puller plates to remove bearings on CAT785, 789 and 793 truck wheel groups. The system uses liquid nitrogen and will remove any of the bearings in 90 seconds or less. The member brought up Donaldson filter issues with respect to air filters. Note Fleetguard and Donaldson inner/outers are not interchangeable. Newmont has recently switched from Fleetguard to Donaldson. Mitch claims that Cashman did an excellent job in the conversion and has been pretty seamless. We have had a few issues with the Donaldson filters that may or may not be totally Donaldsons fault. The operations representative discussed the appreciation to Placer Dome Cortez for the tip on an anti-ratcheting seatbelts. Twin Creeks is going to Greymag seats from Worthern Kenworth and state it is a newer version and requires an adapter plate. Delivery is currently 10 days. They surveyed a group of operators and got overwhelming positive response so the decision to go to this seat was made. Another member asked how the decision was made .did it come from up on high or was it a team effort etc. Dave answered that the operators responses gave justification for the change and the decision was just made. Another member has brought a different angle to the operations group with him having such a strong background in maintenance. Operator training was completed for downhill hauling. The best part is that maintenance personnel were brought in to design the training and deliver the training to the operators. The operations representative talked about the BBSI (behavior based safety initiative) at Twin Creeks and Lone Tree. He cited some recent incidents at Twin Creeks and struggles to tie back the good things of the program when these types of incidents happen.
9:15a.m. to 9:30a.m. Break
9:30a.m. to 10:00a.m. Officer Report Out / Open
REPORT OUT TOPICS
NOTE IF UNABLE TO ATTEND PLEASE SEND A REPLACEMENT PREPARED TO PRESENT YOUR PART
10:00a.m. to Noon Sharing Best Practices Presentations
Noon to 1:00p.m. Lunch break (Provided by WSA)
1:00p.m. to 3:00p.m. Sharing Best Practices Presentations
30-45 minute presentation from ESCO Dealer - High Desert Supply
30-45 minute presentation from Hensley Dealer Interwest Supply
30-45 minute presentation from Berkley Forge Dealer Elko Wire Rope & Mining Supply
3:00p.m. to 3:15p.m. Break
3:15p.m.
to 3:45p.m. General Meeting Review
What worked? What didnt work? Suggested changes of formats, dates, locations, frequency, newsletter, etc. Selection of vendor for company/equipment updates.
3:45p.m. to 4:30p.m. Action Planning
Topic selection process for next WRMMA meeting study groups. 3W review.
Next Meeting Mid July, 2004 tentatively at the Stockmans Hotel & Casino