A comprehensive study at a Cornish clay pit suggests substantial efficiency improvements and cost savings are possible.
- The 18-month analysis by Finning identifies over £600,000 savings through optimised operations.
- Key recommendations include modifying haul routes and enhancing equipment handling to reduce fuel consumption.
- Advanced modelling tools were employed to demonstrate a potential 10% decrease in cycle times.
- Imerys is set to prioritise improvements based on quantified data for maximised benefits.
An extensive time and motion study conducted over 18 months at a Cornish clay pit has unveiled potential savings exceeding £600,000, attributed to operational enhancements identified by Finning, a Caterpillar dealer. This site, which produces 700,000 tonnes of kaolin annually, was thoroughly analysed to pinpoint areas for improvement, including operator performance, haul routes, site conditions, and fleet health.
Observations highlighted several key inefficiencies; sharp turns and gradients over 10% on haul routes notably contributed to increased fuel consumption and prolonged cycle times. In-depth analysis included examining dump area management, job site setup, and challenges posed by legacy stockpiles and varying face heights.
Recommendations offered by Finning emphasised the need to adapt existing on-site routes. By reducing gradients, increasing widths for easier machine passage, and mitigating pinch points, they aimed to lower idle times and fuel consumption significantly. The consultancy provided detailed data catering to optimising fuel usage, minimising equipment wear, enhancing loading efficiencies, and curbing idle times.
Glen Heather, a technical engineer at Imerys, acknowledged the consultancy’s pivotal role in prioritising improvements that promise the highest cost efficiencies. The insights allowed Imerys to accurately quantify savings from potential upgrades such as road widening, aimed at substantial operational efficiency gains across the site. Heather noted their existing awareness of the need for productivity boosts but recognised the previously unmeasured costs linked to inaction.
Ross Marshall, a continuous improvement advisor at Finning, elaborated on the comprehensive nature of their assessment, which employed Caterpillar’s quarry modelling solutions. This technology facilitated simulations that highlighted productivity and efficiency boosts, justified by cost-saving forecasts. Marshall remarked on the importance of recognising how minor adjustments could lead to significant impacts on fuel efficiency and equipment longevity.
The study emphasised on the necessity of addressing long-standing site issues, including steep and narrow access roads. These factors have hindered optimal dump truck operations, introducing inefficiencies as vehicles were compelled to utilise laybys, thereby escalating idling costs.
The strategic recommendations provided by Finning set a clear pathway for Imerys to achieve significant operational efficiencies and cost savings.
