Contamination Control

Nickel Rim South Mine 5-Star Contamination Control Journey

Tim Hinds
Agenda

• GlencoreXstrata
• Sudbury Integrated Nickel Operations
• Nickel Rim South Mine
• Embracing Change
– Through Engagement, Best Practices and
Technology advancement
• Delivering Business Results
• What’s Next?
• Key Takeaways
GlencoreXstrata
 Glencore Global Presence

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 Glencore Diversified Global Operations

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Sudbury Integrated Nickel Operations
 Sudbury Integrated Nickel Operations

Mining Operation
Plant

Strathcona Mill
Fraser Mine
Ni Rim 
South Mine

Smelter

City of 10km
Sudbury

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 Our Values

Entrepreneurialism

Simplicity

Safety

Responsibility

Openness

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 Sudbury Integrated Nickel Operations

• Our employees as well as

contractors worked 13
months
(5 million hours) without a
single lost time injury
in our integrated business
of exploration, mining,
milling, and smelting
activities.

9 // Caterpillar Confidential: GREEN / Global Mining Forum 2014

Nickel Rim South Mine
 Nickel Rim South: Footprint

Wastewater
Shotcrete 115 kV
Collection
Receiving Substation
System
Intake
Main Shaft fans
Headframe

Backfill
Plant

Vent Shaft
Headframe
Exhaust
Fans

11 // Caterpillar Confidential: GREEN / Global Mining Forum 2014

 Nickel Rim South: Underground

MAIN SHAFT VENTILATION SHAFT

7.6m Ø Ø 6.1m
1735m ↕ ↕ 1685m

3 captive levels until 2012

•Garage on each level
•3 mechanics per garage
•1 Supervisor
•1 Material Coordinator CONTACT ZONE
1280 L
FOOTWALL ZONE
1480 L

1660 L

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 Phase 1 Shops: 2007 – 2008

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 Phase 2 Shops: 2008 – 2012

• One shop per level

• Overhead crane
• Central tool box
• Lubrication
dispensing
• Fire suppression
and fire doors
• Two pieces of
equipment
• Small parts
storage area
• Challenges

14 // Caterpillar Confidential: GREEN / Global Mining Forum 2014

 Vision with New Shop – The sell and strategy
Safety
• Ergonomic design
• Larger workspace and storage areas to improve housekeeping

Quality and Reliability

• Extend lifespan of equipment
• Minimized cost per hour of equipment fleet
• Space will enable a more comprehensive component replacement program

Revenue Opportunity
• A decrease in MTTR and breakdowns by improved maintenance practices
• Fleet reduction

Materials Savings
• Proactive maintenance and planned component replacement
• Inventory management of parts and tools in a centralized facility

Improve Labour Productivity

• Active supervision and a centralized workforce will create synergies
• Less contracting out of major work on equipment
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 Planning the New Shop – How Cat partnered up to help us

• 2010 Caterpillar Mine Forum learnings

• Collaboration with Caterpillar and Ron Meischner
• Gap analysis and Caterpillar 5 baseline scoring
• Goal setting – Benchmarking with Surface Shop
• Challenge to achieve Caterpillar 5-Star
Contamination
Contamination Control
Control Per
PerSection
Section
100%
100%
100.0%
100.0%

90.0%
90.0%

80.0%
80.0%

70.0%
70.0%

60.0%
60.0%

% 50.0%
% 50.0% 42%
42%
38%
38%
40.0%
40.0%

30.0% 26%
26% 24%
30.0% 22% 21% 24%
22% 21% 20%
20%
20.0%
20.0% 14%
14%

10.0%
10.0% 0% 0% 0%
0% 0%
0% 0% 0%
0% 0% 0%
0%
0.0%
0.0% rucck

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Section
SectionOf
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TheGuide
Guide
LOW MED HIGH
LOW MED HIGH

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 U/G Maintenance Facilities - Phase 3

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 U/G Maintenance Facilities - Phase 3

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 U/G Maintenance Facilities - Phase 3

Ventilation 
Flow

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 U/G Maintenance Facilities - Phase 3

Wash Bay

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 U/G Maintenance Facilities - Phase 3

Equipmen
t Staging

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 U/G Maintenance Facilities - Phase 3

Shop

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 U/G Maintenance Facilities - Phase 3

Ramp 
Area

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 U/G Maintenance Facilities - Phase 3

Hose Bay
Storage 
Bay
Work Bay

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 U/G Maintenance Facilities - Phase 3

Hand Tool 
Storage

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 U/G Maintenance Facilities - Phase 3

Office and 
Tool Crib

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 U/G Maintenance Facilities - Phase 3

Reference 
Library

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 U/G Maintenance Facilities - Phase 3

Warehouse

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 U/G Maintenance Facilities - Phase 3

2nd Floor 
Office & 
Lunch Room

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 U/G Maintenance Facilities - Phase 3

Bulk Lube 
with 
Kidney 
Looping 

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 U/G Maintenance Facilities - March 2012

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Embracing Change
Through Engagement, Best Practices and Technology Advancement
 Floor Dry – “Low Hanging Fruit”

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 Desiccant Filters

Before After

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 Hose Contamination

Would you use this hose? Today's hose practices! 

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 Kidney Looping

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 Warehousing Improvements

• Protecting our assets:

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 Bulk Fuelling

Before After

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 Technology – Advancing Predictive Maintenance

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 Embracing Change - Setting Expectation

• Shift lineup and PASS

• Checklist sets expectations at the

beginning of every shift
– Allows employees to “Stop and
Correct” immediately

– Comprehensive list covering all

elements of the shop:
• Entry and exit inspections

• Cranes, ramps, floors, barricades,

and stands

• Lighting, housekeeping and garbage

• Storage and stacking

• Bulk lube storage

40 // Caterpillar Confidential: GREEN / Global Mining Forum 2014

 Expectations

• Setting higher standards with best maintenance practices:

– Sampling techniques & particle counting

– Standardized maintenance practices (e.g. Notification process) leveraging planning &

scheduling effectiveness

– Re-wiring PM tasks (objective vs. subjective)

• S·O·SSM training for all personnel

• Component check sheets

41 // Caterpillar Confidential: GREEN / Global Mining Forum 2014

 Training and Sustainability Improvements

• Training:
– OEM training on equipment specific
– Oil sampling techniques
– Basic lubrication
– On-site PSTs (Product Support Technicians)
– Best practices documented
• Testing:
– Particle counting
– Emissions
– Intake systems
• Audits:
– Yearly contamination control auditing
– PM audits
– Safety audits
42 // Caterpillar Confidential: GREEN / Global Mining Forum 2014
 Operator Buy-In

• We explained what contamination control was & how it could

help the Mining teams
• We shared the results with the mining crews
• Told the Miners what they could do to help
• Acted on the ideas that they put forward
• We quickly seen buy in, such as the cleaning of equipment
before it came in for repairs (in most of cases the fellows give
there equipment daily wash downs)
• Less equipment damage due to increased ownership of clean
and well maintained fleet
• They are understanding the benefits of clean fluids and
maintain the fueling and lube areas to a higher standard

43 // Caterpillar Confidential: GREEN / Global Mining Forum 2014

Delivering Business Results
 Caterpillar 5 Audit Score 23% to 96% in 3 years

• Knocking down low hanging ideas created environment of

trust and engagement, inspired creativity among workforce
..*Allowing Change to be embraced instead of resisted*..
Contamination
Contamination Control
Control Per
Per Section
Section
100% 100%
100% 100%
100% 100%
100% 100% 100%
100% 100%
100% 100% 100% 100%
100% 100% 100% 100%
100%
100.0% 96%
96%
100.0%
88% 90%
90%
88%
90.0%
90.0%
78%
78%
80.0%
80.0%

70.0%
70.0%

60.0%
60.0%

% 50.0%
% 50.0%

40.0%
40.0%

30.0%
30.0%

20.0%
20.0%

10.0%
10.0%
0%
0%
0.0%
0.0%

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Section
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LOW MED HIGH
LOW MED HIGH

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 Component Life Extension: Comparison with Baseline

• Baseline (2008):
– Original equipment lifecycle budgets were estimated at this time
– Major components had ~ 2000 hrs reduced lifetime
• Example: engines lasted only 12000 hrs instead of 14000 hrs
• Midpoint (2011):
– Components now lasting expected lifetime
• Today (2014):
– Oil analysis to judge component life:
• > 2000 hrs added to expected lifetime
– Radiator soda washing:
• Expected service lifetime increased from 1000 hrs to 9000 hrs
– $100,000+ in savings

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 Efficiency Improvements: PM Compliance
Able to increase up to 
73% man‐hrs schedule 
for PMs

35% man‐hrs 
were 
scheduled for 
PMs

73%

35%

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 Efficiency Improvements: Unplanned Maintenance Hours

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 Efficiency Improvements: Critical Equipment Availability

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 Efficiency Improvements: Radiator Operating Hours

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 Roadbed Improvements

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 Efficiency Improvements: Equipment Tire Expenditures

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 U/G Fleet Distribution and Reduction

2009 2013
Year

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 Recognizing our Accomplishments: Caterpillar 5-Star

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 Recognizing our Accomplishments: PEM Award

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What’s Next?
 Projected Ore Extraction

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 What’s Next?

• Audits/spot checks
• Fuel system upgrades
• Training and awareness programs
• Continuous improvement of our processes
• Sustainability

58 // Caterpillar Confidential: GREEN / Global Mining Forum 2014

Key takeaways

• Without our new shop we may not

have achieved a “5 star rating”.
However, I believe we would of
taken the challenge on.. the
payback on our improvements
are amazing!

 Safety
 Culture
 Costs
 Equipment availability
 Fleet downsizing
 Credibility
Don’t let the things you can’t do, stand in
the way of the things you can do!
Questions?
© 2014 Caterpillar
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