There are a whole host of simple actions that can be implemented right away that will dramatically reduce production losses during shift-change. We see many of the same issues at our clients’ sites, and the solutions aren’t rocket science. They require effective communication and change management to implement and sustain.
1. Don’t let the operators decide where and when they park up.
This action is the simplest to implement and the most effective. Provide your dispatchers with the training and authority to dictate to the truck operators when they can head towards the park-up areas. That extra five or seven minutes might mean another half or full truck cycle for every truck in the fleet.
2. Create a temporary park-up area near the shovel face.
Rather than having one or two central park-up locations, create safe, temporary park-up areas near the shovel face. Typically, shovel operators are taken to their machines using a light vehicle. Provide the shovel operator with a light vehicle and have two truck operators travel with them. This change has the added benefit of spreading out the trucks, so there isn’t significant bunching of the truck cycles at the beginning of the shift.
3. If mining regulations allow, and it can be done safely, consider parking some trucks loaded.
Safely parking trucks loaded provides additional tonnes at the beginning and the end of the shift. At the end of the shift, it allows the shovels to load trucks right up to the very end. At the beginning of the shift, rather than all trucks being empty and queueing at the shovels, there are also trucks heading to the dump points, allowing the fleet to get into a productive haul cycle quickly. Once the loaded trucks dump their load, a thorough pre-start inspection can be completed.
4. Start the on-coming shift 15 minutes early.
The value of productivity gains from an effective shift-change will dwarf the added personnel costs of an additional 15 minutes per shift. This way, the on-coming operators can be waiting for the truck or shovel to park and begin their shift. Remember: we always want the person waiting on the machine, not the machine waiting on the person.