JIGSAW OVERVIEW

HOW TO CONTROL PRODUCTION ( MINING SOLUTION ) BY PRO-

ACTIVE MANAGEMENT
FLEET MANAGEMENT SYSTEM
Solusi Optimal Produksi dengan memanfaatkan pengendalian alat ( Digger, Truck & Support )
terhadap Operator, Lokasi & Material dengan cara Pro-Active management.
Pro-Active Management :
• Menyediakan waktu lebih banyak untuk Perencanaan kedepan dan antisipasi terhdap
permasalahan.
• Memilah mana yang menjadi tugas dan tanggung-jawab yang bersifat kritikal sehingga kita
bisa membagi skala prioritas pekerjaan dan pendelegasiannya untuk mengoptimalkan
proses, productivitas dan operasional yang lebih efisien.
• Melakukan review terkait proses, termasuk analisa flow komunikasi dan informasi.
• Penerapan teknologi untuk mengoptimalkan efektivitas dan efisiensi, mengidentifikasi
benang merah dan pekerjaan berulang.
• Menganalisa resiko dan mengidentifikasinya dan menetapkan prioritas terhadap
penanganan resiko yang akan ditangani terlebih dahulu.
 KEY PRODUCTION
JUMLAH HOURS
Summary : ( STATUS )
Highlight : Dispatcher Control Status ( Accept or Reject ) & DE Justification
Outcome : Time Management ( Effective Working Hours )
Key Success : Control in Active Status & Operating Delay

TARGET
( VOLUME & PRODUCTIVITY ) Summary :
Highlight : Dispatcher Control Payload & Matching Fleet
Outcome : Capacity ( Payload )
Key Success : Control Under / Over Load

JUMLAH LOAD MUATAN

( ACTIVITY - CYCLE ) ( CAPACITY – TRUCK FACTOR )
Summary :
Highlight : Dispatcher Control Cycle & Matching Fleet
Outcome : Load ( Productivity )
Key Success : Control Effective or Un-Used Cycle include Matching Fleet

JUMLAH JAM ACTUAL ≤ PLAN ; JUMLAH LOAD ACTUAL ≥ PLAN ; BESAR MUATAN ACTUAL ≥ PLAN
SYLLABUS

• IDENTIFICATION CONCEPT
• LOGIC STATUS CHANGE & CYCLE CHANGE
• LOGIC BY DATA
• IDENTIFICATION BY TRIGGER ( STATUS )
• IDENTIFICATION BY TRIGGER ( CYCLE )
• PRODUCTIVITY BY CYCLE
• MF ( MATCH FACTOR )
LOGIC – IDENTIFICATION CONCEPT
ANALYSIS CONCEPT

Summary :
Highlight : HOURS on Frame makin kebelakang ketersediaan makin berkurang
Concept : Bagaimana Fleet Running Sesuai Plan & Setiap Fleet Running lebih Optimal
Opportunity Optimal : Load Count, Truck Count, Capacity
24 HOURS
1

FLEET USED ( MATCH Capacity Bucket & Vessel )

2 FLEET RUNNING

ACTIVE STATUS IN ACTIVE STATUS

3 EFFECTIVE HOURS

PRODUCTIVE NON-PRODUCTIVE

4 LOAD COUNT Key Success :

Guideline : DSP
Highlight : Control STATUS & CYCLE
CYCLE CONTROL

VOLUME
 LOGIC – IDENTIFICATION CONCEPT
ANALYSIS CONCEPT

3
FLEET RANKING
1 Summary :
FLEET 2
Highlight : Rank Shovel based on Hourly Volume
Outcome : Hourly Sequence
Key Success : High frequency Rank on Plan

FLEET RUNNING

Summary : 4
Digger Highlight : Fleet Running based on DSP ( Matching Fleet & Boundary Compliance )
Hauler Outcome : Target Sequence
Key Success : High Total Fleet & Boundary Compliance FLEET OPTIMUM
Support
Summary :
BOUNDARY FLEET TARGET Highlight : Feedback, Follow Up & Escalation Issue or Opportunity ( Double side & Unlocked )
Outcome : Optimum Target & Composite Base
Summary : Key Success : High Target Compliance & Efficiency
Highlight : DSP ( Fleet, Boundary & Target )
Outcome : Target Sequence Summary :
Key Success : Plan Accuracy Highlight : Achievement with Notes
Outcome : Maximum Achievement against Plan
5

FINAL RESULT FLEET

Summary :
Who People Involved : Plant, Engineering, Production
What the Scope Involved : Fleet Running, Productivity, EWH
How People Involved : Pro-Active Management
ADJUSTMENT
6 Summary :
Highlight : Fleet Focus Distribution, Observation based on Priority & Needs
Outcome : Fleet Composite & Prediction
PRO - ACTIVE MANAGEMENT
 06:45:00 LOGIC STATUS CHANGE
SHIFT CHANGE

06:53:20
LOG ON

06:59:40
READY
OB Hauling
Input ( Pelaksaan Perawatan Harian ) P2H

Input ( Hour Meter ) HM

START END
WAKTU SHIFT CHANGE : 00:14:40

06:59:40
READY
OB Hauling

11:57:20
DELAY
Meal & Rest

12:39:30
READY
OB Hauling

START END
WAKTU READY : 04:57:40
START END
WAKTU DELAY MAKAN : 00:42:10
 LOGIC CYCLE CHANGE
ARRIVE
Backing Trigger :
Start : in Dump Beacon, Directional Change / OEM Reversed, Heading above 120’, Speed > 5 and <15 KM/Hour
End : Manual Assign
Queuing Trigger :
Start : Enter Dump Beacon, Speed < 2 KM/Hour Tipping Trigger :
End : Manual Assign Start : In Dump Beacon after Backing, Speed Zero / OEM Vessel Raised Up
End : Depart from Departure Distance

MUATAN

ASSIGN Hauling Trigger :

DISPOSAL Start : OEM other Truck or Depart From Departure Distance
End : Enter Dump Beacon, Speed < 2 KM/Hour
Travelling Trigger : ROAD
Start : Depart from Departure Distance
End : Enter/pass Waiting Distance, Speed < 2 KM/Hour

KOSONGAN
ASSIGN
Waiting Trigger :
Start : Enter/pass Waiting Distance, Speed < 2 KM/Hour ARRIVE
End : Enter Spotting/pass Distance, Directional changed, Heading above 120’, Speed > 5 and <15 KM/Hour

Spotting Trigger :
Start : Enter Spotting/pass Distance, Directional changed, Heading above 120’, Speed > 5 and <15 KM/Hour
End : Enter Loading Distance & Speed Zero / OEM FRONT / BLAST
Loading Single Trigger :
Start : Enter Loading Distance & Speed Zero / OEM
Hanging Trigger : End : Depart from Departure Distance
Start : Last Truck Depart from Departure Distance
End : Next Truck Enter Loading Distance, Speed Zero / OEM
Loading Multi Trigger :
Start : Enter Loading Distance & Speed Zero / OEM
End : OEM other Truck
LOGIC – CYCLE TRIGGER GPS Satellite

A TRAVELLING Identifikasi Posisi ( Trace & Tracking )

Waiting Distance
1 Area Waiting Distance :
Condition :
1. Enter/Pass Waiting Distance [ ✓ ]
2. Speed < 2 KM/Hour [ ✘︎] Spotting Distance
Cycle Occurred :
Still Travelling Time
Hauling Hauling
2 Area Waiting Distance :
Condition :
1. Enter/Pass Waiting Distance [ ✓ ] B
2. Speed < 2 KM/Hour [ ✓ ] 8
Loading
Cycle Occurred :
Change to Waiting Cut Travelling Time Spotting
7
3
Area Spotting Distance : Spotting Travelling Travelling
Condition : 4
1. Enter/Pass Spotting Distance [ ✓ ]
2. Directional ( Heading ) Change [ ✘︎] A
3. Heading above 120’ [ ✘︎] Loading 6 Waiting
5 1
4. Speed > 5 and < 15 KM/Hour [ ✘︎]
Cycle Occurred : Loading Distance
Still Waiting Time
Departure Distance 3
4 2
Area Spotting Distance : Waiting
Condition :
1. Enter/Pass Spotting Distance [ ✓ ]
2. Directional ( Heading ) Change [ ✓ ]
3. Heading above 120’ [ ✓ ]
4. Speed > 5 and < 15 KM/Hour [ ✓ ]
Cycle Occurred :
Change to Spotting Cut Waiting Time
LOGIC – CYCLE TRIGGER GPS Satellite

B HAULING Identifikasi Posisi ( Trace & Tracking )

Waiting Distance
5 Area Loading Distance :
Condition :
1. Enter/Pass Loading Distance [ ✓ ]
2. { by GPS } Speed = 0 KM/Hour [ ✘︎]
3. { by OEM } Material Hit Vessel [ ✘︎] Spotting Distance
Cycle Occurred :
Still Spotting Time Hauling Hauling

6 Area Loading Distance :

Condition : B
1. Enter/Pass Loading Distance [ ✓ ] 8
2. { by GPS } Speed = 0 KM/Hour [ ✓ ] Loading
3. { by OEM } Material Hit Vessel [ ✓ ] Spotting
Cycle Occurred : 7
Change to Loading Cut Spotting Time Travelling
Spotting Travelling

7 Area Loading Distance : 4

Condition :
A
Single Truck by GPS / Distance
Loading 6 Waiting
1. Depart from Departure Distance [ ✘︎] 5 1
Multi Truck by OEM
2. Other Truck Start Loading [ ✘︎] Loading Distance
Cycle Occurred :
Still Loading Time Departure Distance 3
2
Waiting
8 Area Spotting Distance :
Condition :
Single Truck by GPS / Distance
1. Depart from Departure Distance [ ✓ ]
Multi Truck by OEM
2. Other Truck Start Loading [ ✓ ]
Cycle Occurred :
Change to Hauling Cut Loading Time
LOGIC – IDENTIFICATION BY DATA
ANALYSIS CONCEPT

Data Resource : Data Shapes : Data Component :

1. Last Hour Data 1. Time Start or End 1. Time
2. Last 3 Hours Data 2. Duration or Range 2. Cycle
3. Historical Data from 1st Hour Production till Last Hour 3. Frequency & Graphs 3. Load Capacity

Time Data Hierarchy :

1. Time Status ( Active or In Active )
2. Time Category ( Categorize some Description into Productive & Non Productive [ Plan or Un-Plan ] group )
3. Time Description ( identify item that describe Equipment against Operator or Other Fleet or Environment )
4. Time Remarks ( Detail Comment of Description )
5. Reason Category ( Categorize based on Reason Required )

Cycle Data Hierarchy :

1. Shovel Loading
2. Shovel Un-loading & Waiting
3. Shovel Priority & Needs
4. Truck Distribution & Bouncing / Queuing
5. Arrival Frequency & Range in Front / Loading area
6. Non Productive Truck assignment ( Un-Used Location )

Load Capacity Data Hierarchy :

1. Truck Factor
2. Matching Fleet ( Truck Capacity against Bucket Capacity )
3. Payload Distribution ( Dipper & Fix Count )
LOGIC – IDENTIFICATION BY TRIGGER
ANALYSIS CONCEPT

PRODUCTION ZONE

BREAKDOWN – PA %
Identification :
Trigger : Unit Status Change to Maintenance ( Schedule or Un-schedule )
Highlight : Un-Schedule Frequency & Duration

STATUS CHANGE
Identification :
Trigger : Unit Status Change to Non Operation Condition
Highlight : Un-Planned / In-Plan or Budget / Non Budget with No Engine Running
Identification :
Trigger : Unit Status Change to Non Production Condition STANDBY – UA %
Highlight : Un-Planned with Engine Running

OPERATING DELAY – UTIL %

 LOGIC – IDENTIFICATION BY TRIGGER
FRONT & LOADING AREA CONCEPT

1 Front Identification :
Condition :
1. Waiting Time [ ✘︎]
2. Spotting Time [ ✘︎]
3. Loading Time [ ✓ ]
4. Frequency Truck at Shovel [ ✘︎]
Cycle Occurred :
5. Truck Arrive, Truck Frequency Lo to Ideal, Late Loading
6. Truck Arrive, Truck Frequency High, Late Loading

2 Truck Used Identification ( Under - Over ) : 2 Truck Used Identification ( Under - Over ) : 2 Truck Used Identification ( Under - Over ) :
Under Condition : Over Condition : Road / Dump Condition :
1. Hanging Time [ ✘︎] 1. Waiting Time [ ✘︎] 1. Hanging Time [ ✘︎]
2. Waiting Time [ ✓ ] 2. Hanging Time [ ✓ ] 2. Waiting Time [ ✘︎]
3. Speed [ ✓ ] 3. Speed [ ✓ ] 3. Speed [ ✘︎] ( Or )
4. Dumping Time ( Queuing, Backing, Tipping ) [ ✓ ] 4. Dumping Time ( Queuing, Backing, Tipping ) [ ✓ ] 4. Dumping Time ( Queuing, Backing, Tipping ) [ ✘︎]
5. Frequency Truck at Shovel [ ✘︎] 5. Frequency Truck at Shovel [ ✘︎] 5. Frequency Truck at Shovel [ ✘︎]
Cycle Occurred : Cycle Occurred : Cycle Occurred :
6. Last Truck Departure to Next Truck Arrive 6. Last Truck Departure to Next Truck Arrive 6. Last Truck Departure to Next Truck Arrive
7. Truck Arrive, Truck Frequency Lo 7. Truck Arrive, Truck Frequency high 7. Truck Arrive, Truck Frequency Lo and high
8. Match Factor Lo 8. Match Factor High 8. Match Factor Lo to High

3 Material Handling Identification : 3 Material Characteristic Identification : 3 Material Dimension Identification :

Condition :
1. Loading Time [ ✘︎]
2. Spotting Time [ ✘︎] ( with or without )
3. Waiting Time [ ✘︎] ( with or without )
4. Frequency Truck at Shovel [ ✘︎]
Cycle Occurred :
5. Single Side Loading against Matching Fleet
6. Double Side Loading against Matching Fleet
Loading Condition :
1. Bucket Detail – BCM fill per Bucket [ ✘︎]
2. Bucket Detail – Duration among Buckets [ ✘︎]
3. Bucket Detail - Total Buckets [ ✘︎]
Cycle Occurred :
4. Single Side Loading against Matching Fleet
5. Double Side Loading against Matching Fleet
Loading Condition :
1. Bucket Detail – BCM fill per Bucket [ ✘︎]
2. Bucket Detail – Duration among Buckets [ ✓ ]
3. Bucket Detail - Total Buckets [ ✘︎]
Cycle Occurred :
4. Single Side Loading against Matching Fleet
5. Double Side Loading against Matching Fleet
 LOGIC – IDENTIFICATION BY TRIGGER
ROAD, DUMP & MATCHING FLEET AREA CONCEPT

4 Road Identification :
Condition :
1. Speed [ ✘︎]
2. Hanging Time [ ✘︎]
3. Waiting Time [ ✘︎]
4. Frequency Truck at Shovel [ ✘︎]
Cycle Occurred :
5. Truck Arrive, Truck Frequency Lo to Ideal, Late Loading
6. Truck Arrive, Truck Frequency High, Late Loading

5 Dump Identification : 5 Dump Identification : 5 Dump Identification :

Structure Condition : Dimension Condition : Method Condition :
1. Queuing Time [ ✘︎] 1. Backing Time [ ✘︎] 1. Backing Time [ ✘︎]
2. Backing Time [ ✘︎] 2. Queuing Time [ ✘︎] ( with or without ) 2. Tipping Time [ ✘︎]
3. Tipping Time [ ✘︎] 3. Tipping Time [ ✘︎] 3. Queuing Time [ ✘︎] ( with or without )
4. Frequency Truck at Shovel [ ✘︎] ( with or without ) 4. Frequency Truck at Shovel [ ✘︎] ( with or without ) 4. Frequency Truck at Shovel [ ✓ ]
5. Frequency Truck at Dump [ ✘︎] 5. Frequency Truck at Dump [ ✘︎] 5. Frequency Truck at Dump [ ✘︎]
Cycle Occurred : Cycle Occurred : Cycle Occurred :
6. Last Truck Departure to Next Truck Arrive 6. Last Truck Departure to Next Truck Arrive 6. Last Truck Departure to Next Truck Arrive
7. Truck Arrive, Truck Frequency high 7. Truck Arrive, Truck Frequency high 7. Truck Arrive, Truck Frequency Lo to high

6 Matching Fleet Identification :

Condition :
1. Truck Factor [ ✘︎]
Cycle Occurred :
2. PA Hauler Type by Ratio against DSP Type Locked
LOGIC – PRODUCTIVITY BY CYCLE
SHOVEL PRODUCTIVITY

Truck Factor :
Condition :
1. Truck Capacity Summarized based on Payload Full time Range :
against Material Type Condition :
1. 60 minutes in Hourly Full Time

TF ( TRUCK FACTOR ) X 60
SHOVEL PRODUCTIVITY = ---------------------------------------------
( LOADING + HANGING TIME in Minutes )

Hanging Multiple Trigger :

Loading Single Trigger :
Start : Last Truck Depart from Departure Distance
Start : Enter Loading Distance & Speed Zero / OEM
End : Next Truck Enter Loading Distance, Speed Zero / OEM
End : Depart from Departure Distance

Loading Multi Trigger :

Start : Enter Loading Distance & Speed Zero / OEM
End : OEM other Truck
LOGIC – PRODUCTIVITY BY CYCLE
SHOVEL PRODUCTIVITY

Full time Range :

Truck Factor : Condition :
Condition : 1. 60 minutes in Hourly Full Time
1. Truck Capacity Summarized based on Payload
against Material Type Effectivity :
Condition :
1. ( Total time Ready – Total Hanging Time in
Hours ) dibagi 60 menit

TF ( TRUCK FACTOR ) X 60 X E
SHOVEL PRODUCTIVITY = -------------------------------------
( LOADING TIME in Minutes )

Hanging Multiple Trigger :

Loading Single Trigger :
Start : Last Truck Depart from Departure Distance
Start : Enter Loading Distance & Speed Zero / OEM
End : Next Truck Enter Loading Distance, Speed Zero / OEM
End : Depart from Departure Distance

Loading Multi Trigger :

Start : Enter Loading Distance & Speed Zero / OEM
End : OEM other Truck
 LOGIC – MATCH FACTOR
MATCH FACTOR

SCOPE OF WORK : Waktu Travel Hauler dalam keadaan kososngan

Productivity by Cycle Waktu Hauler diisi terhitung Material menyentuh ( Single Distance )
Vessel sampai keluar dari Departure Distance

Jumlah Hauler yang di gunakan

nTRUCK X LOAD
MF ( Match Factor ) =
nSHOVEL X ( SPOT + LOAD + HAULING + BACKING + TIPPING + TRAVELLING )

Waktu Preparasi Hauler Maneuver ke Area Loading

Truck ( Multi Distance & Trigger ) Waktu Hauler diisi terhitung Waktu Hauler Dump
Waktu Hauler Maneuver Material sampai keluar dari
Material menyentuh Vessel sampai
keluar dari Departure Distance Dumpingan

Total Waktu IDLE Shovel menunggu sebelum mengisi

Truck ( Material masuk ke Vessel ) Waktu Travel Hauler dalam keadaan muatan
( Multi Distance – Departure )

SHOVEL IDLE TIME = HANGING TIME

 LOGIC – MATCH FACTOR
MATCH FACTOR

SCOPE OF WORK :
Waktu Travel Hauler dalam keadaan kososngan
Productivity by Cycle Waktu Hauler diisi terhitung Material menyentuh ( Single Distance )
Vessel sampai keluar dari Departure Distance
Waktu Hauler diisi terhitung Material menyentuh
Waktu Preparasi Hauler Maneuver ke Area Loading Vessel sampai keluar dari Departure Distance
Truck ( Multi Distance & Trigger )

( SPOT + LOAD + HAULING + BACKING + TIPPING + TRAVELLING )

HANGING TIME = - LOAD TIME
nTRUCK

Jumlah Hauler yang di gunakan

Waktu Hauler Dump
Waktu Hauler Maneuver Material sampai keluar dari
Dumpingan

Total Waktu IDLE Shovel menunggu sebelum mengisi

Truck ( Material masuk ke Vessel ) Waktu Travel Hauler dalam keadaan muatan
( Multi Distance – Departure )

SHOVEL IDLE TIME = HANGING TIME

 KESIMPULAN
• Menjaga kecepatan Optimal.
• Sebisa mungkin mengurangi waktu Delay atau Standby.
• Jumlah Load dan Jumlah Jam Ready yang tidak sesuai akan mempengaruhi pencapaian
Productivity.
• Dumping tidak sesuai arahan berpotensi mengurangi jarak.
• Digger mengganti mengganti Material sebelum Truck First Bucket.

Note Terkait Productivity dan Jarak pada Dispatch

• Menekan Layar sesuai aktivitas atau kondisi actual. Untuk area otomatis, jika tidak berubah
setelah sampai di Front atau Dumpingan, lakukan tekan manual.
• Pastikan harus Tekan Assign dari Dumpingan untuk bisa terhitung 1 load Truck dan Truck
dapat penugasan baru dan diidentifikasi kosongan agar ketika di Digger bisa Tekan Bucket
Pertama.
• Antri berpotensi mengurangi load Truck dan Gantung berpotensi mengurangi load Digger.