Analysing the Utilisation Effectiveness of Mining Machines Using Independent Data Acquisition Systems: A Case Study

Abstract

Growing competition in the market for energy raw materials needed for power generation has led to an increasing number of measures being undertaken in the mining sector to reduce the unit costs of mining production. One of the areas that offer considerable savings in this regard is the utilisation of the technical resources owned by mines. This article is therefore focussed on analysing the utilisation effectiveness of these machines, based on the data recorded by industrial automation systems, as well as on measurements from independent surveying and chemical analysis of the excavated material’s quality. For this purpose, a methodology was developed to use the data about the operational parameters of the machines in order to analyse the effectiveness of their utilisation. It was assumed that the reliability of this assessment would depend mainly on the quality of the data used to conduct it. It was also assumed that using independent data sources for the analysis would provide objective and reliable information on the operation of the machines, devoid of any subjective feelings of the personnel or other factors. The developed methodology, based on a modified Overall Equipment Effectiveness (OEE) model, was used to analyse four machines that comprise the automated longwall system. Values were determined for each machine, including their availability, performance and product quality. This, in turn, made it possible to determine a total effectiveness indicator, based on a modified Overall Equipment Effectiveness (OEE) model, for the particular machines and the entire technical systems they form. The obtained results were used to assess the effectiveness of their utilisation and recommend corrective measures aimed at improving this metric. Moreover, the analysis results made it possible to assess the utilisation status of the machines in question. They also served as the basis for determining further lines of research, the purpose of which is to improve the effectiveness of the mining sector. The obtained results indicated that this process requires the wide application of IT tools, especially for data archiving and analysis. These tools, along with the developed model and methodology based on the analysis of large volumes of digital data, are in accord with the activities related to the implementation of Industry 4.0 idea in mining. It is the authors’ opinion that the material at hand should find a wide range of practical applications in supporting the management of technical resources within the mining sector.