Tyre Awareness Program

Report
December 2005

Distribution : A Price, P Rod, E Emilza, B Jones, B Siahaan, S Josal, Y Sitanggang, R Brown,

A Ferguson, D Triono, B Palmer, J Hurst, P Ludlow, S Chamber, A Stewart, P Grouhel, T Gray,
T Bulmer, G Zuvich, N Parsons, A Karim, R McKenzie, J Haryanto, C Goodwin, H Sutoyo,
D Russel
CONTENTS PAGE

1. Executive Summary …………………………………………………………. 1

2. Introduction …………………………………………………………………… 2
3. Objective ……………………………………………………………………………. 2
4. Sangatta ……………………………………………………………………………. 3
4.1 Presentation ……………………………………………………………… 3
4.2 Comments ………………………………………………………………….. 3
4.3 Recommendations ……………………………………………………. 3
5. Satui ………………………………………………………………………………. 4
5.1 Presentation ……………………………………………………………… 4
5.2 Comments ……………………………………………………………….. 5
5.3 Recommendations …………………………………………………… 5
6. Senakin ……………………………………………………………………………… 6
6.1 Presentation ……………………………………………………………. 6
6.2 Comments ………………………………………………………………… 6
6.3 Recommendations …………………………………………………… 7
7. List Of Finding From Operator Response ……………………….. 8
7.1 General Hauling Conditions ……………………………………… 8
7.2 Haul Road Conditions ………………………………………………. 9
7.3 Haul Road Width ………………………………………………………. 10
7.4 Haul Road Maintenance ………………………………........... 11
7.5 Loading Areas ………………………………………………………. 12
7.6 Dumping Areas ………………………………………………………. 13
7.7 Tyre Pressure Checks …………………………………………….. 14
7.8 Tyreman/Workshop Responsiveness ………………………. 15
7.9 Supervision Responsiveness ………………………………….. 16
7.10 Operator Comfort …………………………………………………. 17
8. List Of Finding From Supervisor Response …………………. 18
8.1 Global Tyre Crisis ……………………………………………………. 18
8.2 Impact OF Global Tyre Crisis ………………………………….. 19
8.3 Problem In Maintaining Work Areas ……………………… 20
8.4 Summary Of Supervisor Problems ……………………….. 21
8.5 Tyreman/Workshop Responsiveness ……………………… 22
9. Charts Of Participants Comment …………………………………. 23
9.1 Operator Comments ……………………………………………… 23
9.2 Supervisor Comments ……………………………………………. 24
10. Reference …………………………………………………………………….. 25

LIST OF APPENDICES

Appendix A - Operator Questionnaire

Appendix B - Operator Feedback Form
Appendix C - Operator Comments
Appendix D - Supervisor Questionnaire
Appendix E - Supervisor Feedback Form
Appendix F - Supervisor Comments
 Tyre Improvement
Awareness Road Show

1. Executive Summary

Off highway tyre supply has reached the crisis stage. It is anticipated that
this situation will remain so until at least the end of 2006. We all must
acknowledge this, be aware of the consequences and take affirmative
action to minimise disruption to production.

The Mine Engineering Group undertook the process of socialising the

situation to all people involved, targeting those who are engaged in daily
activities which influence tyre life. As such, a Tyre Awareness Package was
developed in conjunction with the TCI Tyre Advisor. Two different
awareness presentations were created targeting Operators and
Supervisors.

The awareness packages were delivered to personnel at Sangatta, Satui

and Senakin. A total of 250 Operations personnel attended the sessions.

As a part of the awareness packages all participants completed feedback

forms. The most common issues that were highlighted across all 3 sites
were:
• Utilisation/ lack of support equipment
• Payload Optimisation
• More support from Tyre crew
• Better socialisation of tyre issues
• Support from management

It is intended that this document will facilitate and assist senior

management in better understanding the main issues that are believed to
affect tyre life at their mine site.

December 2005 1
 Tyre Improvement
Awareness Road Show

2. Introduction

To provide site personnel with information’s and knowledge’s of tyre global

crisis, failure cause and identification of working area which influence tyre
life, Tyre Awareness Sessions were held on:

- 5th-6th September at Sangatta

- 13th-14th September at Satui
- 16th-17thSeptember at Senakin

A total of 250 people attended the tyre awareness training across the 3
sites. At the completion of each session each attendee completed a
multiple choice feedback form. The results from the feedback surveys
were compiled and have formed the basis of this report.

All future attendees will complete Feed Back Forms and they will be sent to
the MEG for review. A Report will be provided for sites and related TCI
personnel and an action plan will be derived from the report.

3. Objective

The aim of the project was to initiate a Tyre Awareness Training Package at
each site that would make site personnel aware of the ‘Global Tyre Crisis’
and the influence of work environment/conditions on tyre life.

The aim of the operator presentations was to:

• Provide awareness about the common tyre failures at their site

• Provide information to operators about the major operational
areas which cause premature failures.
• Encourage operators to be actively involved in best practices to
achieve Optimum Tyre Life.

The aim of the supervisor presentation was similar to the operator

package, but with more emphasis on:

• Motivating both operators and supervisors to be actively involved

in best practices to increase tyre life.
• The influence of haul road design on tyre life.

Secondly the aim was for Site Tyre Supervisors and Operator Trainers to
gain exposure in delivering the package so as the program could be
handed over to site and presented to Operations Personnel who were
unable to attend the initial sessions.

December 2005 2
 Tyre Improvement
Awareness Road Show

4. Sangatta

4.1. Presentation

Presentation dates : 5th-6th September

Contact Person : Peter Pickering - Tyre Supervisor because
Peter Rod as the first contact person was
on leave.
Co- Presenter : Herry Sutoyo – Tyre Supervisor
Team support : Sangatta Training Centre and Dean Russel –
Operator Trainer

5th September
One session was delivered at Porodisa for 10 attendees. The
participants included Superintendents and Expatriates. The
Presentation was delivered in English with Bahasa Indonesia on the
slides because half of the attendees were National staff.

6th September
A presentation was given to Operation Trainers and Supervisors at
Porodisa. In total 22 people attended, including Dean Russel and
Peter Pickering. In the second half of the session one of the operator
trainers delivered the awareness material.

4.2. Comments

… There were comments regarding lack of support equipment. For

example, the amount of time graders were being used to tow
lighting towers for night shift preparation.

… There were suggestions to include the tyre material in the Safety

Day Presentations, but Joe Stelmach said it should be separate.
However, there will be a 2 hour session after the Safety Day
presentations.

… There will need to be 100 sessions to cover approximately 1500

operators at Sangatta which will be completed by Operator
Trainers and Tyre Supervisors.

4.3. Recommendations

… Investigate the comments regarding lack of support equipment.

Determine if there is supporting evidence. Take the relevant
actions based on the results.

December 2005 3
 Tyre Improvement
Awareness Road Show

5. Satui

5.1 Presentation

Presentation dates : 13th-14th September

Contact Person : Bosar Siahaan – Deputy Mining Manager
Co- Presenter : Joko Haryanto – Leading Hand - Tyres
Team support : Satui Training Centre

13th September
Bosar Siahaan arranged the schedule as follows:

• 08.00 - 10.00 hrs - for trainer and operator

• 10.00 - 12.00 hrs - for supervisor + superintendent
• 13.00 - 15.00 hrs - for trainer and operator
• 15.00 - 17.00 hrs - for supervisor, FM and LH

The presentation was held at Abimanyu pit Mining Control. Additional

operators from Mulia pit attended. In total 70 operators attended the
Tyre Awareness sessions at Abimanyu.

14th September
The presentation was held at Yudistira Mining Control. Personnel
from Yudistira, Antasena and Mulia pits attended.

There were two sessions conducted. They were:

• 08.00 - 10.00 hrs - for trainer and operator

• 14.00 - 16.00 hrs - for trainer and operator

Joko Haryanto – Tyre Leading Hand,

also had opportunity to deliver
presentation for operators in the
afternoon session.

A total of 58 operators attended the

sessions at Yudistira.

December 2005 4
 Tyre Improvement
Awareness Road Show

5.2 Comments

… Excellent planning by Bosar who created a schedule of activities

and ensured that the Tyre Awareness Program ran effectively.

… Satui has already instigated Tyre Awareness training for

operators. The new tyre awareness material will be delivered
by Operator Trainers at mining control during wet weather
delays.

… Many Operators mentioned that it was accepted practice to

speed to avoid situations where excavators are waiting on
trucks.

… Most Excavator operators expressed difficulty in loading trucks

to the correct payload. Complaints were made that payload
indicator lamps were difficult to see.

… Some superintendents stated that the Awareness Program was

excellent and it needs commitment and support from
management, to be followed up and implemented on site.

… Supervisors and Superintendents complained about lack of

support equipment.

… National Supervisors and Superintendents felt that there was

unreasonable pressure from expatriate superintendents
regarding excavators waiting on trucks, even in situations
where dozers are cleaning up the loading floor.

5.3 Recommendations

… Maximum speed signs must be placed at appropriate areas

throughout the mine. Operators must drive the equipment to
the conditions and no more than the advised speeds. Reducing
speeds by limiting gear selection on equipment should be
considered.

… Ideally the excavator operators should know the payload of the

truck they are loading to optimise payloads. Alternative
Payload Display Systems on loading tools should be considered.

… Investigate the comments regarding lack of support

equipment. Determine if there is supporting evidence. Take
the relevant actions based on the results.

December 2005 5
 Tyre Improvement
Awareness Road Show

… Commitment and support from management are required to

encourage people to carry out the jobs as per standards
practices.

6. Senakin

6.1 Presentation

Presentation dates : 16th-18th September

Contact Person : Russell Brown – Plant Operations
Superintendent
Co- Presenter : Iswaluyo – Tyre man Supervisor
Team support : Senakin Training Centre and Amarullah
Karim (Ahjab) – Snr.Mining Supervisor

15th and 16th September

Ahjab coordinated the program because Agus Effendi – Mine
Superintendent was on secondment.
Two sessions were delivered to 19
people at the Training Centre.
Attendees included Operators,
Supervisors and mining engineers.

17th and 18th September

Presentations took place at Pit 2 Mining
control. In total 71 operators joined the
program over the 2 day period.

6.2 Comments

… Support from site personnel was very significant to coordinate

participants (operators) to attend the program.

… Iswaluyo – Tyre Man Supervisor had the opportunity to deliver

one presentation for operators. He was very confident and is
ready to deliver this program in the future at Senakin. Ficky
Tulong – Operator Trainer was also mentioned to deliver this
program in the future with Iswaluyo.

December 2005 6
 Tyre Improvement
Awareness Road Show

… Many truck operators complained about having no radio

communication in their trucks. This presents a number of
production and safety issues.

… There was a major focus on production at the site with little

attention being paid to overloading of trucks. Some of the
comments from the operators were:

o Digger operators have responsibility to load trucks until

full, disregarding whether it was overloaded.
o Supervisors will complain if the load is not full to
overloaded.
o Operators were also questioning the use of hungry
boards.

Complaints were made that payload indicator lamps were

difficult to see by digger operators.

… Operators were concerned about speeding. There are no

maximum speed signs in many areas. Truck operators
commented that they were travelling ‘as fast as possible’ to
avoid the excavator from waiting on trucks. The operators said
there was pressure from supervisors to ensure all excavators
have trucks.

6.3 Recommendations

… Radios should be installed on all mobile equipment, so they can

communicate with their supervisors if there is a problem with
tyres, the roads, loading and dumping areas and even unsafe
conditions. Information about their payload could also be
provided to the excavator operator while they are loading to
avoid under and over loading.

… Ideally the excavator operators should know the payload of the

truck they are loading to optimise payloads. Alternative
Payload Display Systems on loading tools should be considered.

… Maximum speed signs must be placed at appropriate areas

throughout the mine. Operators must drive the equipment to
the conditions and no more than the advised speeds. Reducing
speeds by limiting gear selection on equipment should be
considered.

December 2005 7
 OPERATORS FEED BACK

How are the general hauling conditions in your pit area?

All Sites Satui Senakin Sangatta

2%
4%
20%

2%
31% 1% 8% 86%
1%
8%

83%
74% 66% 14%
Very good Good

Poor Very Poor

Comments
Satui - 67% of operators surveyed said their general hauling conditions were either good or very good
Senakin - 91% of operators surveyed said their general hauling conditions were either good or very good
Sangatta - 100% of operators surveyed said their general hauling conditions were either good or very good

Data was obtained from Operators in September 2005.

December 2005 8
 OPERATORS FEED BACK

How would you describe the typical haul road conditions?

All Sites Satui Senakin Sangatta
6% 1%
22%
18%
6% 2% 9%
21% 41% 1% 14% 7%

22%
24% 29%

25%
5% 29%
12% 24%
20% 21%

41%

Too many rocks on the road

Too many rocks and undulations on the

road
Comments
Some Rocks
Comments
Satui - Biggest issue was 'rocks' at 30%
Too many undulations
Senakin - Biggest issue was 'rocks' at 34%
Sangatta - Biggest issue was 'rocks' at 36%
Average

Smooth
Data was obtained from Operators in September 2005.

December 2005 9
 OPERATORS FEED BACK

How would you describe the typical haul road width?

All Sites Satui Senakin Sangatta

1% 7% 2% 3%
8%
25%
29%
25%

42%

65% 3%
69% 71%
49%

1%

Too Narrow
Comments
Narrow Satui - 75% of operators described the haul roads as Narrow
Senakin - 28% of operators described the haul roads as Narrow
Wide enough Sangatta - 29% of operators described the haul roads as Narrow

Very wide

Some are narrow

Data was obtained from Operators in September 2005.

December 2005 10
 OPERATORS FEED BACK

Is the haul road in your work area maintained (graded)?

All Sites Satui Senakin Sangatta

49%

45% 38%
36%

55% 64%

51%
62%

Yes

Sometimes/not so often

Comments
Satui - 51% of Operators believe their work area was sufficiently maintained
Senakin - 64% of Operators believe their work area was sufficiently maintained
Sangatta - 38% of Operators believe their work area was sufficiently maintained

Data was obtained from Operators in September 2005.

December 2005 11
 OPERATORS FEED BACK

Describe your typical loading area?

All Sites Satui Senakin Sangatta

6% 1% 6%
6% 3% 7% 11% 8%
12% 23%

30%

39%
52%

70% 69%
57%

Very good

Good Comments
Satui - 45% of operators believe their typical loading area is poor
Poor (very rocky or too much water or Senakin - 19% of operators believe their typical loading area is poor
undulations) Sangatta - 69% of operators believe their typical loading area is poor

Very poor (too many rocks / water or

undulations)
Fairly good (not too many rocks / water
or undulations) Data was obtained from Operators in September 2005.

December 2005 12
 OPERATORS FEED BACK

Describe your typical dumping area?

All Sites Satui Senakin Sangatta

5% 6%
3% 3% 43%
7% 9%
21% 26% 11%

68%
73%
57%
68%

Very good
Comments
Good Satui - 29% of operators believe their typical dumping area is poor
Senakin - 18% of operators believe their typical Dumping area is poor
Poor (too rocky or too much water or Sangatta - 43% of operators believe their typical dumping area is poor
undulations)
Very poor (too many rocks / water or
undulations)
Data was obtained from Operators in September 2005.

December 2005 13
 OPERATORS FEED BACK

How often are your tyre pressures being checked?

All Sites Satui Senakin Sangatta

2%

2% 3%
33% 18%
43%

42%

56%

65%
79%
57%

Each shift
Not so often
Very seldom

Comments
Satui - 56% of operators said their tyres were being checked each shift
Senakin - 79% of operators said their tyres were being checked each shift
Sangatta - 43% of operators said their tyres were being checked each shift

Data was obtained from Operators in September 2005.

December 2005 14
 OPERATORS FEED BACK

Responsiveness of Tyre man/Workshop to action on reported problems

All Sites Satui Senakin Sangatta

2% 3%
1% 8% 8%
27%
41%

58%
47% 51% 70%

84%

Quick action

Slow action

Very slow

Comments
Satui - 41% of operators believed the Tyre Crew were quick to action on problems reported
Senakin - 70% of operators believed the Tyre Crew were quick to action on problems reported
Sangatta - 8% of operators believed the Tyre Crew were quick to action on problems reported

Data was obtained from Operators in September 2005.

December 2005 15
 OPERATORS FEED BACK

How responsive is your supervisor in taking action to repair poor roads?

All Sites Satui Senakin Sangatta

52% 21%
48%
45%

55%
48% 52%
79%

Actioned quickly Actioned slowly

Comments
Satui - 48% of Operators believe their supervisor is responsive in taking action to repair poor roads
Senakin - 48% of Operators believe their supervisor is responsive in taking action to repair poor roads
Sangatta - 21% of Operators believe their supervisor is responsive in taking action to repair poor roads

Data was obtained from Operators in September 2005.

December 2005 16
 OPERATORS FEED BACK

Describe your comfort when operating your machine

All Sites Satui Senakin Sangatta

3%

22% 6%
23% 19%
41% 14%
42% 29%
48%
1%

1%

1%
32%
29%
57%
32%

Average comfort

Comfortable
Comments
Very comfortable Satui - 29% of operators feel uncomfortable
Senakin - 19% of operators feel uncomfortable
Uncomfortable Sangatta - 29% of operators feel uncomfortable

Very Uncomfortable

Data was obtained from Operators in September 2005.

December 2005 17
 SUPERVISORS FEED BACK

Are you aware of the Global Tyre Crisis?

All Sites
All Sites Sangatta Satui Senakin

0% 22%
10%

11%

90%
100% 78%
No
89%
Yes

Comments

Satui - 90% supervisors were aware of tyre crisis that is happening in global.
Senakin - 78% supervisors were aware of tyre crisis that is happening in global.
Sangatta - All supervisors were aware of tyre crisis that is happening in global.

Data was obtained from Operators in September 2005.

December 2005 18
 SUPERVISORS FEED BACK

Do you know what the impacts of the Tyre Crisis are on our operations?

All Sites Sangatta Satui Senakin

22% 11%
10%

14%

78% 90%
89%
No
86%
Yes

Comments

Satui - 10% supervisors did not have any ideas about the impacts of tyre crisis to TCI operation . This proportion of supervisors is also similar with that
of who were not aware of tyre crisis recently occurred.
Senakin - 11% supervisors didnot have ideas about the impact of tyre crisis to TCI operation.
Sangatta - Even all supervisors were aware of the tyre crisis that recently happened, but there were 22% supervisors who did not know the impacts to TCI operation.

Data was obtained from Operators in September 2005.

December 2005 19
 SUPERVISORS FEED BACK

Do you have any problems maintaining your working area (ex. Loading point, dumping area or haul road)?

All Sites Sangatta Satui Senakin

0%
44%
56%
33%

44%
56%
100%
No
67% Yes

Comments

Satui - 56% supervisors had dificulties in maintaining their workarea.

Senakin - 44% supervisors had dificulties in maintaining their workarea.
Sangatta - All supervisors had dificulties in maintaining their workarea.

Data was obtained from Operators in September 2005.

December 2005 20
 SUPERVISORS FEED BACK

What are your problems?

All Sites Sangatta Satui Senakin

40%
12%
33% 33%
46% 25%
7%
3% 17%

3%
3% 3%
24% 12% 17%
7% 17%
Lack of equipment 20%
13% 7% 25% 33%

lack of operator and not competent.

Loading area is too narow, ( te get coal Comments

quickly )
Satui - 33% supervisors had dificulties in maintaining their workarea caused by lack of equipment.
Material is too soft. Senakin - Supervisors had dificulties in maintaining their workarea,33% caused by lack of equipment and
another 33% caused by responsible area too broad.
Sangatta - 46% supervisors had dificulties in maintaining their workarea caused by lack of equipment.
Operator is not competent

Responsible area is too broad

Time for coaching and traing are limited

caused by operator is focused to work.
Unsupported Designs/Planning from
engineering Data was obtained from Operators in September 2005.

December 2005 21
 SUPERVISORS FEED BACK

Is the Tyre man/Workshop responsive/quick to action problems that operators report, such as tyre pressures or other tyre
technical issues?

All Sites Sangatta Satui Senakin

52% 30%
44% 13%

56%
70% 87%
48%
Slow actioned
Yes, Quick actioned

Comments

Satui - 70% of supervisors believed the Tyre Crew were quick to action on problems reported
Senakin - 13% of supervisors believed the Tyre Crew were quick to action on problems reported. It was a significant diference with the operator feed backs
on the same question.
Sangatta -56% of supervisors believed the Tyre Crew were quick to action on problems reported

Data was obtained from Operators in September 2005.

December 2005 22
OPERATOR COMMENTS

4 Top 5 - Operator Comments

6 All Sites
1 Top 5 - Operator Comments
1 Sangatta
11 31

1 5

23 4

More support from tyre crew required More support equiment required More support equiment required More support from tyre crew required

More supervisors required Overcome overloading issues More supervisors required Overcome overloading issues

Better tyre awareness socialisation required Better tyre awareness socialisation required

2 Top 5 - Operator Comments 2

Top 5 - Operator Comments
3
Satui Senakin
2
5
7

20

16
7

More support from tyre crew required More support equiment required More support from tyre crew required More supervisors required

Overcome overloading issues More supervisors required More support equiment required Better blasting material required

Better tyre awareness socialisation required Need Commitment from Management

23
SUPERVISOR COMMENTS

1 Top 4 - Supervisor Comments

All Sites Top 4 - Supervisor Comments
1
6 Sangatta
10 1

3
8

More support from tyre crew required More support equiment required
More support equiment required Better tyre awareness socialisation required

Better tyre awareness socialisation required More supervisors required More support from tyre crew required More supervisors required

Top 3 - Supervisor Comments Top 3 - Supervisor Comments

1
3 Satui Senakin

More support from tyre crew required More support equiment required More support from tyre crew required Better blasting material required

Better tyre awareness socialisation required Roof should be put on tyre stock.

24
 10. Reference

• Earthmover Tyre Shortage Global Crisis

Tony Cutler – Technical Manager, Otraco International Pty.Ltd
www.otraco.com

December 2005 25
 Tyre Improvement
Awareness Road Show

Appendix A
Operator Questionnaire

December 2005
 Tyre Improvement Initiatives
Operator Feed Back Form

Cat Truck 773 – 777 – 785 – 789

Komatsu Truck HD465 – HD785 – Excavator
Type of
equipment 530 Grader
being operated Liebherr Truck T252 Wheel Loader
Water Truck

Site SATUI – SENAKIN - SANGATTA

Pit Area

Circle the best answer.

1. How are the general hauling conditions at your pit area?

a. Very good c. Poor e. Fairly good
b. Good d. Very Poor

2 How would you describe the typical haul road at your Pit area?
a. Too many rocks on the road e. Average smooth
b. Average number of rocks on the road f. Smooth
c. Many undulations g. Very smooth
d. Not too many (average ) undulations
3. The haul road at your are working is :
a. Too Narrow d. Very wide
b. Narrow e. Some are narrow
c. Wide enough

4. How comfortable are you when driving on the haul road at your pit area?
a. Average comfort d. Uncomfortable
b. Comfortable e. Very Uncomfortable
c. Very comfortable
5. Is the haul road at your area maintained (graded)?
a. Yes
b. Sometimes/not so often
c. No

6. In your opinion, how responsive is your supervisor in taking action to repairing bad roads?
a. Actioned quickly
b. Actioned slowly
c. No action

7. How do you describe your Loading area?

a. Very good
b. Good
c. Poor ( rocky or have water or undulations )
d. Very poor (too many rock or have water or undulations )
e. Fairly good ( not too many rock or have water or undulations )
8. How do you describe your Dumping area?
a. Very good
b. Good
c. Poor ( rocky or have water or undulations )
d. Very poor (too many rock or have water or undulations )

Tyre Improvement Initiatives Page 1 of 2

 Tyre Improvement Initiatives
Operator Feed Back Form

9. How often is the Tyre man checking your tyres pressure?

a. Each shift
b. Not so often
c. Very seldom
10. Is the Tyre man/Workshop responsive/quick to action problems you report, such as tyre pressures
or other tyre technical issues?
a. Yes, Quick actioned
b. Slow actioned
c. Too slow actioned

11. If you have any comments or complaints regarding the tyre issues at your site, please write in the
box provided below.

Tyre Improvement Initiatives Page 2 of 2

 Tyre Improvement
Awareness Road Show

Appendix B
Operator Feedback Form

December 2005
 Tyre Improvement
Awareness Road Show

Appendix C
Operator Comments

December 2005
Operator Feed Back
No Site Comments

1 Sangatta Need graders which will grade the road regularly.

2 Sangatta It was ocurred so often where operator grader was

called by supervisor to fix undulution on haul road but
when he was working, another supervisor called him to
tow lighting tower because of blasting activity.

3 Sangatta Dozer should always available at loading point. it need

enough grader to maintain haul road and need
improvement in communication between Supervisors
and operators regarding working environment
conditions.

4 Sangatta Need support special equipment to tow lighting tower (

zonder). At moment grader used to tow the ligting tower
when blasting will be commenced

5 Sangatta Wheel Dozer is good to maintain loading point.

6 Sangatta Truck is required to not too fast when drive near road
which still been maintained to make graders or dozer
can work safely and properly.

7 Sangatta Tyre routine inspection must be carried out by plant.

Need dozer on each loading point. Need additional
grader to maintain the road and not to tow lighting
tower. Supervisor must be available ofr each loading
point.

8 Sangatta Although it has been writen on operator checklist but it

was slow actioned. Poor road maintenance and No
dozer at loading area.

9 Sangatta Many of tyreman did not check tyre properly. It was

happened so often tyreman just checked the outsides
tyres only or even just asking the HM of unit for their
reports.

10 Sangatta It would be better if tyreman always at pit like at pit J.

But they must be equiped with compressor. It would be
better also if tyreman always giving input/information
regarding road condition at pit area. Not just stand by at
workshop

11 Sangatta Supervisor must take care working area and responsive

to operator report regarding tyre.

12 Sangatta I hope payload of the trucks are not over and always
maintain loading area.

Thursday, 17 November 2005 Page 1 of 6

Operator Feed Back
No Site Comments

13 Sangatta Supervisors should need training regarding tyre issues

so then they can pass the information to their
information.

14 Satui Please add grader and Wheel Dozer for loading Point

15 Satui Need additional support equipment like graders the

road and wheel dozers for loading points.

16 Satui Lack maintainance at loading area because of lack

support equiments , dozer, wheel dozer and also poor
blasting result ( too bigger ).

17 Satui Need additional Graders and Dozers.

18 Satui Need additional Graders and Compactors since Satui

mine is get bigger/wider.

19 Satui Lack of dozer and grader

20 Satui Small number of grader for wide area. Many

supervisors gave order when the task for road
maintenance was not finish yet.

21 Satui Need additional Graders, Compactors and Dozer.

22 Satui Slow action to tidy up loading point. Grader need

always maintain haul road.

23 Satui Need another grader, since at mulai only one grader.

Not Overload

24 Satui Dozer is lack of supervision at loading point. Grader

utilisation is not effective, especially at nignt. Lack of
supervision. Dozer allocation at loading point not suit
with type of material.

25 Satui Need additional grader at Mulia. At moment only one

and when it break down, 2-3 days with no grader. Tyre
man need doing check at mulia more often, not once a
week .

26 Satui Need a dozer on each loading and dumping area.

27 Satui Some tyres being operated with cut on it. This is

dangerous condition for operators. Need spare grader
for road maintenace purpose.

28 Satui Nedd additional WD or Grader.

Thursday, 17 November 2005 Page 2 of 6

Operator Feed Back
No Site Comments

29 Satui Need another grader, since at mulai only one grader.

30 Satui Need to put cover/roof on all stock tyres at hanoman.

MA of equipment must be high enough so they can be
used to maintain road, Loading and dumping area.

31 Satui Need a better tyres to maximise tyre life.

32 Satui Need regular inspection from tyre man at Mulia Pit on

each shift start.

33 Satui Need a quick action from tyreman

34 Satui Need tyreman to do tyre inpection at Mulia on each shift

start

35 Satui Mechanics must responsive to operators report

36 Satui Need quick action from tyreman if there is a report from

operator regarding tyre. It would be better If there is a
system that can make operator know if the tyre already
checked by tyreman on each shift start, such as tagging
or note put on tyres or operator cabin.

37 Satui need inspection on track from mechanics.

38 Satui Please always maintain Loading point and haul road.

Need improvement service from Tyreman.

39 Satui Tyreman need carry out inspection on tyres everyday.

40 Satui Control tyre pressure regularly. Need spare grader to

anticipate high downtime.

41 Satui Add tyreman crew so they can doing inspection on

each shift start. Need a payload monitor by Excavator.

42 Satui Every 1 or 2 days need inspection by tyreman at mulia.

12-13 September, no grader at mulia.

43 Satui Tyre man must doing inspection on every shift start

44 Satui Please check tyre pressure for equipments at road

maintenace on each shift start.

45 Satui Slow action from tyreman. Tyreman must put a tag if a

tyre already inspected so make operators do not
reported them on each shift change.

Thursday, 17 November 2005 Page 3 of 6

Operator Feed Back
No Site Comments

46 Satui Need a quick action from tyre man if there is report

from operator regarding tyres.

47 Satui Please improve blasting material. Too big. Tyreman

must give information to operator regardjing the tyres
that can operated.

48 Satui Need quick action from tyreman if there is a report from

operator regarding tyre. Please change tyres if they are
already worn out or have many cuts. Don't wait until
they are blown out as it is unsafe condition for
operators.

49 Satui Tyre crew need carry out inspections on each shift

changes then put a note to explain if tyres are safe for
operation.

50 Satui Sometime tyreman advised to continue operate the

equipment even though the tyres were not safe to be
operated.

51 Satui Grader tyres need to be replaced if already worn out.

Worn out tyre can make grader sliped.

52 Satui Appointed 1 special lh/Supervisor to control road

condition , loading and dumping area.

53 Satui Need better maintain on loading area as main priority.

54 Satui Many undulutaions on each haul road that used to

illegal mines.

55 Satui Do not need Hungry Board on the trucks. Need payload

system on excavator which detect truck payloads.
Possibly we need reduce the truck payload but off
course as on mining manager approval.

56 Satui Plaese activate payload meter on excavator. Cut off

hungry board to avoid overload.

57 Satui Just cut the hungry boards as it will cause an overload.

58 Satui Hungry board is the cause of truck Overload.

59 Satui Overload is a common problem. The road is not good,

too many corners. Over speed is often occurred to
avoid excavator waiting.

60 Satui Improve blasting to make easy to tidy up loading point.

Pay load data need repair.

Thursday, 17 November 2005 Page 4 of 6

Operator Feed Back
No Site Comments

61 Satui too icrrease tyre life need awreness from operator to

work as per standart procedures.

62 Satui This awareness Program need to be socialised to all

supervisors level up who always not follow procedures
only for production.

63 Satui Time available for prestart check is too short ( not

enough time for pre start check )

64 Senakin 1 operator for 1 equipment, don't always changes.

65 Senakin Good team work to improve tyre life.

66 Senakin Need additional support equipments.

67 Senakin Need a proactive respose froM GradeR and Dozer

operators.

68 Senakin Most of coal loading area are wet.

69 Senakin Need a better team work among operators and

superviors. Not over load the trucks.

70 Senakin Need additional trucks to avoid speeding.

71 Senakin Need commitment from management between mining

and plant.

72 Senakin Need commitment from up level to down to implement

best operation practices.this awareness program need
to be implemented.

73 Senakin It will be good if tyreman can check tyres every shift at

crib time.

74 Senakin It better for tyreman crew to check tyre more regular.

75 Senakin Need quick action from tyreman if there is a report

from operator.

76 Senakin Tyreman must keep up good working

77 Senakin Reports from operator sometime mean nothing,

tyreman or supervisor just ask the unit should be
operated.

78 Senakin Tyre man must be responsive/quick actin when there is

a report from operator.

Thursday, 17 November 2005 Page 5 of 6

Operator Feed Back
No Site Comments

79 Senakin Some basalt stones are identified at pit 16. Tyreman

need carry oput regular inspection on tyres at this pit 16.

80 Senakin Please give attention to loading points.

81 Senakin Continous maintenance on the road ,loading and

dumping point is a must.

82 Senakin Need supervision on each loading points.

83 Senakin Loading and dumping area must clean from rocks.

84 Senakin Loading and dumping area must clean from rocks.

85 Senakin Need radio on the truck. Need more supervisor.

86 Senakin Need additional supervisor to keep up watching loading

and dumping area.

87 Senakin Senakin is faily good.

88 Senakin Poor blasting material ( too big ) and hard to dig.

89 Senakin Poor blasting material ( too big ) and hard to dig.

90 Senakin Road is priority to be maintained. Brake performance

also important, sometime there was a retarder that
brake suddenly when being activated, this caused the
tyre dragging on the road.

91 Senakin Thanks for this sozialisation.

92 Senakin Need more training ( like this awareness ) for operation

supervisors. Need good team work to increase tyre life,
not only give pressure to operators. Tyre Bonus.

93 Senakin Implement tyre bonus for operators.

Thursday, 17 November 2005 Page 6 of 6

 Tyre Improvement
Awareness Road Show

Appendix D
Supervisor Questionnaire

December 2005
 Tyre Improvement Initiatives
Supervisor Level - Up Feed Back Form

Site SATUI – SENAKIN - SANGATTA

Responsible
Pit Area

Please circle your answers

1. Do you know about Tyre Crisis which is occurred globally?
a. Yes
b. No

2. Do you know what is the impact of that Tyre Crisis to our operational ?
a. Yes
b. No
If Yes, please specify

3. Do you have any problems maintaining your working area (ex. Loading point, dumping area or
haul road)?
a. Yes
b. No

( If your answer is No, please continue to No.5 )

4. What are your problems? (you may select more than 1 answer)
a. Lack of operators
b. Operator is not competent
c. Lack of equipment
d. Responsible area is too broad
e. Unsupported Designs/Planning from engineering
f. others, please explain

5. Is the Tyre man/Workshop responsive/quick to action problems you report, such as tyre pressures
or other tyre technical issues?
a. Yes, Quick actioned
b. Slow actioned
c. Too slow actioned

6. If you have any comments or complaints regarding the tyre issues at your site, please write in the
box provided below.

Tyre Improvement Initiatives Page 1 of 1

 Tyre Improvement
Awareness Road Show

Appendix E
Supervisor Feedback Form

December 2005
 Tyre Improvement
Awareness Road Show

Appendix F
Supervisor Comments

December 2005
Supervisors Feed Back
No Site Comments

1 Sangatta Lack of Support equipments, such as Dozers, Graders.

2 Sangatta Lack of Dozers.

3 Sangatta Need additional dozers. At moment 1 dozer to handle

from loading point until dumping area.

4 Sangatta Lack of Support equipments, such as Dozers, Graders,

also need special supervisor for road loading and
dumping points maintenance

5 Sangatta No tyre inspection for night shift,please do it regularly.

6 Sangatta Need special supervisor for road, dumping and loading

point maintenance.

7 Sangatta Operators still need more training to icrease their skill

and competency. Need a special supervisor for road,
loading and dumping point maintenance.

8 Sangatta Need sosialisation of this tyre crisis to all operators, eq.

in toolbox talk. Need additional support equipments.
Improve operator competency through training.

9 Sangatta Supervisors should have knowledges of how to operate

tyre efficient and safer.

10 Satui Graders are always break down and could not utilize.
Locations of work are too broad plus grader must use
3rd gear to be operated.

11 Satui Lack of Support equipments, such as Dozers, Graders.

12 Satui Tyres are need to check by tyreman regularly

13 Satui Tyre Supervisor should have a list of units that can be

operated ( the tyres are good ) on each shift to avoid
slow shift start because of many operator radio/reports
about their tyres to ops.supervisors or workshop.

14 Satui Need tyreman on each area where truck be operated,

so they can take a quick action to the tyre problem
whenever it's arise.

15 Satui Tyreman must put a note on the equipment when they

finish from inspection, to avoid slow shift start because
of many operator radio/reports about their tyres to
ops.supervisors or workshop.

Thursday, 17 November 2005 Page 1 of 2

Supervisors Feed Back
No Site Comments

16 Satui Need tyre regular inspection by tyreman. Need

improvement at loading and dumping area. Improve
communication between operators, supervisors. Mine
design must support and consider tyre aspects.

17 Satui Ops.Supervisor must be able to quick to Identify

problem of their working area. Need additional suport
equipments. Improve tyre training for all operators.
Support from tyreman.

18 Satui Proactive from supervisors to maintain their working

area. Prestart check is a must for operators. Need tyre
training for all operators. Lack of suport equiment, such
as grader.

19 Satui Need commitment from management. Need tyre

training for operator in operation techniques which can
safe the tyre and other components. Roof should be
placed on tyres stock. Need inspection from tyreman on
each shift start, crib time.

20 Senakin Need a quick action from tyreman to operator reports.

21 Senakin There is no good communication between supervisors

tyreman and operation. Need an audit which carry out
by Tyreman, mining and engineering.

22 Senakin Need work environment inspection regularly by plant

and operation.

23 Senakin Tyreman must proactive to carry out inspection of

loading,dumping area.

24 Senakin Poor material blasting ( too big ) sometime.

25 Senakin Roof should be put on tyre stock.

Thursday, 17 November 2005 Page 2 of 2