Aggregates Manager Digital Magazine
Issue link: http://read.dmtmag.com/i/815541
Production Loading at the Quarry Face OPERATIONS Best Practices T he difference in movement when observing an excel- lent loader operator versus an average one is similar to watching someone perform ballet versus a hip hop type of dance. They are very different and distinct motions. "One dance has constant stopping and starting, and the other is very smooth," says Eric Yeomans, product manager, General Purpose Equipment (GPE), Volvo Construction Equip- ment. "Ballet is very fl uid. It's similar to looking at a very good loader operator. When I see jerky, unin- terrupted reaction, that's when you can instantly spot someone who is struggling or hasn't had enough time on the machine for a good comfort level operating it." "It's pretty dramatic when you see someone that is good," he continues. "It's very easy to spot." In addition to smooth operation, the expert operator is taking in other considerations that ensure optimal equipment operation. "There is no ex- tra stress put on the machine and no overuse of fuel and power," Yeomans explains. "Most customers are tracking cost per operator. A good operator makes a difference." Working in blasted rock, especially at the quarry face, may be one of the toughest and harshest environments in which a machine can operate; that is why the production loader operator can be one of the most important roles in a quarry. It's critical for operators to not only be able to properly and effi ciently operate these machines, but also understand every aspect associated with working at the quarry face. "The operator has to be extremely aware of wheel spin and how much throttle and horsepower is being applied," says Chris Connolly, product manager, GPE products, Volvo Con- struction Equipment and a seasoned operator trainer. "Keeping a smooth underfoot is also absolutely critical." Communication between the operator and driver must be constant to keep distance as short as possible. "Productivity goes down if you're transporting rock farther than you have to," Connolly adds. Minimizing the distance traveled to and from the face can also help pre- vent equipment downtime. Following a blast, it's not uncommon to fi nd sharp pieces of material in the loading area. "This is tough on tires and on gas," he says. "You need to make sure the trucks keep moving with the most effi cient route. If a truck is sitting idle, waiting, or an operator is not doing his best to get the bucket loaded properly, this all factors into poor pro- ductivity and fuel usage — and time is money." Failing to keep the correct bench height, as well as maintaining safe space for excavators to swing and safe distance from the high wall, are also mistakes that are important to note. "To prevent issues and keep the worksites safe, we directly address this with repetitive discussion and demonstration," explains Erin Waldron, aggregates supervisor for Cemex USA's Brooksville Quarry. AGGREGATES MANAGER The operator needs to be aware of a machine's oper- ating power. This means being aware of wheel spin — i.e. revolutions per minute and how much throttle and horsepower are being applied. Applying too much power can cause the equipment's wheels to slip. This could result in the need to re-grade the underfoot and production fl oor and create unnecessary downtime. Awareness should also consider safety aspects, such as an area that needs to be graded again. Provide thorough training with a seasoned production loader operator or trainer to develop the necessary skills. Use of simulators can be effective and help de- velop skills to operate the equipment with deliberate, fl uid motions, and to do so comfortably. Trainers should also observe trainees to examine their assertiveness with trucks, whether they are communicating with the haul truck drivers, and whether they have a situational awareness for issues that could affect safety and pro- ductivity. Provide thorough training Monitor power consumption 1 4