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Article history: The paper presents selected results of the adaptation of Lean Manufacturing methods to the
Received 19 January 2015 mining industry conditions. The research was carried out within the framework of R&D
Accepted 23 July 2015 project ‘‘Adaptation and implementation of Lean in the copper mines.’’ The article focuses
Available online xxx on the key issues related to the Total Productive Maintenance. TPM in a mine according to
Authors' approach should be based on 3 main pillars: improvement of the environment of
Keywords: work, autonomous and planned maintenance and standards in development.
Total Productive Maintenance In order to adapt TPM method to mining conditions several steps were taken. In the first
Lean Manufacturing step failure analysis was conducted. On the basis of its results, a pilot group of machines was
Mining industry selected. To ensure the best environment for implementing the method a holistic approach
Maintenance was applied. Three types of activities were performed in parallel – designing a room for pilot
Management area machines, daily service process optimization and repair standardization.
The coherent TPM methodology developed within the framework of Lean Mining project
is so universal that it can be successfully implemented in the other mining companies,
specializing in the underground and open pit mines and quarries, in order to increase their
profitability and introduce continuous improvement approach.
# 2015 Published by Elsevier Sp. z o.o. on behalf of Politechnika Wrocławska.
* Corresponding author. Tel.: +48 71 320 43 84; mobile: +48 608 17 11 12.
E-mail address: joanna.helman@pwr.edu.pl (J. Helman).
http://dx.doi.org/10.1016/j.acme.2015.07.002
1644-9665/# 2015 Published by Elsevier Sp. z o.o. on behalf of Politechnika Wrocławska.
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
Table 1 – Comparison of specificity of the mining and the automotive industry [7].
Mining industry Automotive industry
Work of customers cannot be stopped, thus The assembly line can be stopped, so transformation
production at the mine is the push system to pull system is possible
Continuous production Production in cycles
Unstable/variable operating conditions Stable operating conditions
Variable work environment Permanent work environment
Geological hazards can stop the production No environmental threats to production
High volatility of the availability of materials Controlled availability of materials
Large dispersion of work (up to several km) Working in a relatively small factory
Mine customers are other industrial companies Sales of products primarily to individual customers
could be comprehensively applicable in other mining compa- This is why the Authors assumed that, after proper adaptation,
nies. implementation of LM (including TPM) should be possible and
What needs underlying is the fact that Lean, being part of in the long period of time beneficial and profitable for the
management field, forces the researchers who deal with mines. MI competitiveness could be enhanced by using some
related issues, to work on living objects (organization, elements of LM, which basic message is to avoid any kind of
company, etc.). Production management differs from others waste through continuous improvement of the entire compa-
sciences because it touches simultaneously aspects belonging ny and its environment, by elimination of the non-value-
to areas of technology, economy and HR. Therefore research added activities [7]. LM is widely used in many industries,
conducted in this field always needs to be very practical and especially in the manufacturing and automotive industry,
applicable. Implementing LM to a mine, just like many other where it brings great results in improving production and
scientific problems related to MIs and their needs, stems from business processes, which in turn leads to cost reduction,
the lack of clear guidelines or methods which would processes flexibility enhancement and competitive advantage
consistently describe how to address such issues [20]. gain [23]. To elucidate the distinctness of the MI, a comparison
Presented paper refers to the conducted research in the of specificity of the mining and the automotive industry is
scope of Total Productive Maintenance (TPM). The main goal of presented in Table 1.
this article was to answer the question how to adapt TPM Presented comparison clearly shows why LM, especially
method to mining environment and implement it underground. TPM, needs special adaptation before it can be implemented in
What is more the paper tries to fill the gap of scientific guidelines the MI. The paper presents the summary on Authors approach
describing how to approach implementing TPM in a mine in the developed to adapt and implement selected elements of TPM.
way it is applicable and replicable by other mining entities.
The main aim of the research presented in the paper was
2. TPM adaptation
limited by several constraints. First of all, despite numerous
publications on TPM, literature related to the problem
addressed in the paper is very limited. This is why critical The aim of TPM is to improve machines' effectiveness by:
evaluation of advantages and disadvantages of different
approaches on TPM implementation in the mines is nearly - early equipment management and maintenance prevention,
impossible. Moreover, the MI is far different from other types - shifting the routine activities of machinery operation and
of industry. The MI in which earth-moving plays a fundamen- maintenance for their operators [8],
tal role is constantly under pressure to improve productivity, - increase the engagement of employees participation in
efficiency and safety [1]. The MI, like other sectors of the global those processes [7,14].
economy, is a subject of the general laws of market economics.
However, due to its specific character, it adapts in a different When failures and defects are eliminated, the rate of
way to the needs of modern management concepts. Without operating speed of machines will rise, operating costs will be
taking into consideration the specific nature of the MI, dealing reduced and productivity will increase [2,15].
with the issues of economic efficiency may lead to erroneous While analyzing different sectors of economy, it can be
decisions and actions. Besides all changes, both technological noticed that especially companies from the underground MI
and managerial, that could be made in a mine have to be suffer from very high machines failure rate [10]. It is caused by
conformant with the mining law. In particular underground very specific environment – defined as all the external variable
mining is far different from other industries, which is mainly physical conditions among which a technical object operates
caused by the fact that the manufacturing process is carried [16] – in which machines work: they are in almost constant
out in the natural environment, thus is characterized by high motion, break down very often due to high temperatures, high
volatility and uncertainty. This affects directly the technology level of humidity and poor state of routes. The environment is
used to operate, the organization of the production process particularly important, because it is the factor that the mostly
and its continuity in time. Nevertheless, taking into account influences on the failure rate. TPM adaptation and implemen-
full advantage of the horizontal nature of manufacturing tation should be a solution to high failure frequency problem.
technologies and management methods, allows further TPM in a mine, in comparison to standard ‘‘TPM House’’,
application of existing methodologies into other industries. according to Authors' approach should be reduced to 3 main
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
3. Data analysis
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
Fig. 5 – 3D CAD models of the spares and hydraulic hoses storage systems.
spares in the HMC. If the inventory level is minimum, the where they are refilled, then he (or she) may return to other
milkman carries an empty container (or Kanban card – duties. After implementing this solution min. and max. values
depending on the part type) to the warehouse and after should be revised at least once a month during the first two
collecting proper parts, transports them back to the HMC quarters and corrected until their level is optimum. Proposed
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
Fig. 7 – HV's room 3D CAD model and its implementation in the HMC.
solution regards only one HMC, so in order to notice benefits of CAD modeling is appropriate for all areas of engineering
pull system implementation the solution needs to be spread to design, which creates the design and construction documen-
the other HMCs as well. In the long term this system should tation based on the 3D models [3]. The project included toolbox
optimize spares management so that waste is eliminated and with full equipment for HV mechanics, detailed engineering
costs minimized. However it needs to be underlined that projects of operators' and mechanics' cabinets and designed
implementing RPS rules requires a lot of effort and resources spares storage system. The dedicated room was developed
(in the initial phase) from the management team. according to Occupational Safety and Health terms, ergonomic
Implementing PSR should limit bullwhip effect which is and 5S2 rules and technical requirements of mine workers
typical when spares demand is forecasted. Errors of forecasts suggestions. The room was designed in the way that enables
increase in the successive links in the logistic chain. To ensure efficient and secure operation of HVs' maintenance and
reduction or even elimination of the bullwhip effect it is services (Fig. 7).
necessary to implement PSR not only in the HMC, but also in One of the stages of 5S implementation is the use of visual
the warehouses, both placed underground and on the surface. control (VC). The so-called ‘‘Method of Painting’’ is used for
marking horizontal and vertical surfaces. Especially in the
4.2. Room dedicated for HV's mechanics and operators mine it must meet the requirements for ensuring safety on
facility transportation paths defined in: Government Regula-
Another task carried out within TPM was designing a special tion of Labor and Social Policy on the general safety and health
room for HV mechanics and operators in the pilot HMC where regulations, Polish Standard PN-68/M-78010; and also techni-
a dedicated, empty space was selected. It enabled designing cal requirements for escape routes. Therefore, the guidelines
the room without any obstacles and any previous incon-
veniences. After defining and classifying equipment necessary
for different types of work, a 3D CAD model of a room was 2
5S stands for sorting, stabilizing, sweeping, standardizing and
designed in the optimum way. It is generally stated that the 3D sustaining the practice [17].
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
for VC in the HMC were developed according to the 5S and the basis for defining the operational motion semantics to
mentioned regulations. Some examples are presented in Fig. 8. generate human motions in a digital environment [11]. It helped
not only to define the DS standard and determine its normative
time, but also to describe and optimize the DS process.
5. Autonomus and planned maintenance –
The analysis based on previously recorded video of the DS
HVs' daily service standardization
performed by an operator and HV's operation and mainte-
nance manual. The information in the manual indicates only
Within the task ‘‘Standardization and improvement of checkpoints, it does not give answer to the question in what
designated and mapped processes’’ standard of HV daily order DS should be performed. Fig. 9 presents observed values
service (DS) was developed. The DS is a set of supervisions of the DS real times for 5 HVs and the standard time calculated
performed before the machine leaves to work. within the MTM.
Observation of the DS processes showed that its real time The analysis allowed to determine the optimal DS
varies a lot – the scatter of times is relatively big. Every operator operator's course (Fig. 10) – starting from reading information
conducts the DS on their own way. The lack of standardization is in the Machine's Workload Book (MWB), through an inspection
clearly visible. To solve this problem the MTM (UAS) method was of machine's various components, up to entering new
used [24]. Measurement of working time in the MTM is used as information to the MWB. Besides, the standard enables the
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
operator to detect and eliminate HV faults. Thus the actual continue these activities on their own. In this part of the
availability of the machines will be increased and so will mine project, team members performed site visit to the mine in
production, as well as the safety of the work. order to observe the overhaul of the hub, replacement of
bearings, seals, brake disc and brake manifolds in one of the
HVs, which was documented by video footage, pictures and
6. Standrds development written description of all activities performed by mechanics.
Analysis of the data collected during the execution of
6.1. Vehicle repair standardization repairs was carried out, schematic description of standard
procedures was prepared and subsequently the standards'
The idea within the standardization of machine's repair along template was developed. The whole analysis of film, photos
with a description of its procedure was not only to develop a and notes were divided into nine stages – preparatory
model standard, but also to define the way of designing other operations, wheel removing, hub disassembly, parts cleaning,
repair's standards, so that after the project, miners could seals and brake disc assembly, hub and brake manifolds
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
assembly, fluid and lubricants refilling, wheel assembly and 1. wastes caused by lack of spares including:
termination operations, and each step consisted of a number of - repair time extension,
different activities. A description of all 65 operations describing - disorganization of work,
hub's repair covers information about the work place, the - machine's unavailability,
number of required mechanics, the time required for the task's - threat that the production plan will not be executed,
execution, the required spares and tools. An illustration was - shortage cost,
added to each description to present the operation properly. The 2. excessive inventories of spares:
entire repair's standard includes a list of all the necessary tools, - generating excess and holding costs,
spares, materials, fluids and lubricants, and media necessary to - causing depreciation,
perform the repair (Figs. 12 and 13). - and space problems.
The repair time calculated on the basis of created standard
is 273 min which is close to the minimal time (270 min) What is more it should also limit or eliminate bullwhip effect,
identified in 73 observations described in DCS. The maximum which is typical if spares demand is forecasted. Described
real repair time was 450 min and the average was 445.41 min. advantages together with implementation of HVs daily service
Fig. 11 presents a comparison of repair time of the HV's hub. and repairs standardization should in the long term bring
It clearly shows that implementing standard to overhaul economic profits related to decrease of machines' failure rate
process can shorten the average time nearly twice. Develop- and repair time reduction. Expected benefits include increased
ment of standards for other repairs can thus significantly profit due to increased machines' productivity and reduction of
improve overhaul processes i.e. through eliminating useless operating costs (especially storage costs). Additionally, imple-
operations. Due to the fact that the standard presents best mentation of TPM steps can bring other, non-economic benefits,
practices of repair processes it can play a role of a handbook such as increased safety of miners and facilitation of repairs
and be a helpful tool for new mechanics. thanks to work standardization and designing of special room
What is more, the procedure of preparation the repair for HV mechanics and operators.
standardization was created. The template is so universal that The assessment of the developed methodology on TPM
it can be successfully used to describe other machinery's implementation in the mining industry is quite hard due to the
overhauls as well as activities related to the repairs. fact that this undertaking did not have many predecessors. In
fact only few examples of research on Lean implementation in
6.2. Training programmes mining companies were described worldwide. In Poland
research on this scale was done for the first time.
In this task TPM/5S training materials for employees were The distinguishing feature of the approach on TPM
developed and training was conducted for all underground implementation presented in the article is that it was
employees from the pilot area. The duration of this training performed in the scientific way by adapting Lean methods
was approximately 15 min, and its time was planned to not to and tool used in manufacturing industry, based on literature
interfere with the ongoing work. The best period was the shifts review, into new field of underground mining industry.
changes, which allowed to participate in the training all HMC Obviously management of the mine and miners also took
employees. Training focused on the place and the role that 5S part in the project and advised developed concepts, neverthe-
method plays in lean organization, TPM with its pillars and a less the whole methodology was elaborated in the scientific
list of best practices. In addition, every mechanic and operator manner. Combining scientific knowledge and practical aspects
received printed presentation, to be able to, once again, get of mining work allowed achieve synergy, knowledge transfer
acquainted with its contents. During the training potential and development of miners competence in the field of LM,
implementations places were discussed. especially TPM approach. Employees who participated in the
project became members of the newly established Lean Team
and leaders in the implementation of the new approach. To
7. Conclusions
assure that developed approach is applicable and replicable by
other mining entities all the proposed solutions were
The industrial and academic worlds seem to agree that described with appropriate models, standards, algorithms
implementing LM is beneficial in every company. However, and procedures. The coherent TPM methodology developed
it also needs to be stated that it is not easy to foresee the within the framework of this project is so universal that it can
impact of such implementation in strictly monetary terms, be successfully implemented in the other mining companies,
because it usually takes time and cannot be observed specializing in the underground and open pit mines and
immediately after implementation. Implementing LM in a quarries, in order to increase their profitability and introduce
company prepares it for continuous and sustained improve- continuous improvement approach.
ment and creates disciplines and operational capabilities that
are in fact hard to value and quantify [18]. This is why the
direct economic results of the Lean adaptation and imple- Acknowledgements
mentation in the mine presented in the paper are yet
unknown. However, it is expected that the approach described The research was conducted within the project ‘‘Adaptation
in the paper will bring several benefits. Pull system imple- and implementation of Lean Methodology in copper mines’’
mentation should definitely limit or eliminate two types of co-financed by the Polish National Centre for Research and
wastes related to spare parts: Development – grant no. NR09-0011-10/2011.
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002
ACME-327; No. of Pages 12
Please cite this article in press as: E. Chlebus et al., A new approach on implementing TPM in a mine – A case study, Archives of Civil and
Mechanical Engineering (2015), http://dx.doi.org/10.1016/j.acme.2015.07.002