The first of six papers showing how a mining enterprise supported by a maintenance organization performing at the “world-class” level stands to reap many benefits including sustained, continuing productivity and profitability. Over the course of this series, the actions needed to achieve world-class mining maintenance status are explained in six consecutive steps that lead to recognition as a first-rate organization with productive employees performing quality work, and consistently reliable equipment to meet production and quality goals. Developed by Paul D. Tomlingson, maintenance management expert and author of the book, “Maintenance in Transition—The Journey to World-class Maintenance,”

Learn about the misconceptions Americans have about energy, “fracking” and the natural gas and oil industry. Americans’ energy misconceptions can have a direct negative impact the industry and our country’s future. From the author of Just the Fracks Ma’am, the Truth about Hydrofracking and the Next Great American Boom. AUDIO ONLY.

Originally presented at Haulage & Loading 2013. Too often, haul truck operator trainees don’t retain enough of the knowledge they learn during training. That can lead to longer on-boarding cycles, lower productivity and potential safety problems in the mine. Blended learning – providing training via multiple modalities using a highly structured, building-block approach – shows promise in addressing this challenge. This paper highlights insights gathered over a three-year period from mines in North America and provides examples of blended learning in action.

Originally presented at Haulage & Loading 2013. This white paper explores proximity detection in the open pit mine being used effectively as an operator assist strategy which improves digging production through enforcement of best practices, although it is normally thought of first as a safety tool, and second as a step toward full automation when combined with object avoidance.

The authors describe the application of remote isolation systems in mining industry conveyance systems and offers case study details where these systems have been installed.

Overview of arc-preventative motor control centers and how they enhance personal safety, protect equipment and support more reliable operations.

The mining industry is a competitive business with operators competing to uncover every advantage. Perhaps the biggest step forward could come from an unlikely source. Read about 10 things you may not have known about LED lighting in mining operations.

Immersive Technologies has released further detailed verified results arising from their work with key mining customers. In partnership with mine management teams across Australia, North America, Latin America, Africa, Europe and Asia Immersive has delivered dozens of Continuous Improvement (CI) projects that have helped miners control costs, lift productivity and maintain safety standards. Verified in-pit gains over the last 12 month period include: US$1,100,000 haul truck fuel savings for a North American Mine 72% reduction in machine abuse events for a North American Mine US$500,000+ fuel savings at an Indonesian Mine US$770,000 tire life savings at an Indonesian Mine 68% reduction in haul truck down time for a Latin American Mine 4.9% spot time improvement at a Latin American Mine 31% reduction in equipment abuse events at an Australian Mine 5.1% excavator dig rate improvement at an Australian Mine 13% reduction in breakdown hours for excavators at a European Mine 72% reduction in breakdown hours for wheel loaders at a European Mine US$400,000+ Fuel savings in a Brazilian Mine 28% reduction in tire replacements saving US$1,500,000 in a Brazilian Mine 99% engine fire pass rate – global average after training

WorksiteVR™ has a relatively low cost of delivery with training environments that can be customized to deal with many worksite training challenges. • High learner retention and recall levels – Learning environment is highly focused, highly memorable and free from distractions. • Multiple learning style compatibility (seeing, hearing, doing) – To cater for various adult learning principles • Safe learning environments – No risk to personnel or property, educate learners in relation to hazards and their potential consequences. • Portability – Transported in a small suitcase sized package.

Cipta Kridatama Talent Development Manager, Gemilang Adi Perdana, said “with commodity prices going down, like many sites, we are looking at ways to cut costs and fuel consumption was identified as problem area. We were over budget by nearly 10,000 liters per month at one site and identified the contributors affecting fuel consumption. Operator skill level was the focus of the fuel efficiency efforts,” Perdana said. Fuel records for 30 haul truck operators were collected over a one month period and 18 of the 30 were over the budgeted liters per hour consumption. All operators were assessed using an Immersive Technologies, Advanced Equipment Simulator to establish a baseline, simulation based training then occurred followed by a reassessment. Once operators passed the reassessment they were put back in the field. After one month operators were assessed again to confirm retention of the new haul truck operating techniques.

Training for the Safest Operations: • Practice for a range of possible emergency situations in a safe environment • Increase confidence in reacting to emergencies • Significantly reduce your risk of LTIs and fatalities • Compliance Refresher Training

Everyday thousands of operators across the world begin their shift by assessing and responding to equipment issues before they begin operations but how can mine sites be sure pre-start inspections are properly completed and that safety, machine uptime and maintenance costs have not been compromised? A new interactive and virtual tool from Immersive Technologies has been launched to ensure effective and consistent training and assessment of operators on machine inspection routines. Early detection of equipment that is unsafe or worn saves on maintenance costs and reduces likelihood of injury, downtime or environmental damage. The new Pre-Start Inspection tool by the world leading mining simulation technology provider, Immersive Technologies, trains and assesses mining personnel on the correct identification and actions to be taken in relation to equipment issues. This tool allows operators to demonstrate competency when real world training is not possible and where mistakes are costly if undetected.

With over 100,000 operator training sessions analyzed we know that less than 50% of experienced operators can recall the procedure to respond to an emergency machine failure. We can deliver over 90% pass rates through Immersive Technologies’ proven training solutions.

Steep declines in the price of coal have placed an emphasis on existing operators improving their productivity by improving cut sequences. Using an IM360 Advanced Equipment Simulator from Immersive Technologies an experienced operator trainer first observed the operators in the field and then operated the Continuous Miner to observe the unique conditions present at each of the mines. The trainer then developed a tailored curriculum within simulation, replicating coal tensile strength, rock bands, top height and other significant operational characteristics.

Hexagon Mining is the only company to solve surface and underground challenges by integrating design, planning, and operations technologies for safer, more productive mines. With its commitment to shape smart change, Hexagon Mining does not just imagine bridging the gap between short-term planning and operations, connecting eet operations with mine planning, or making analytics and business intelligence holistic and universal - it is making these solutions a reality.

MineSight 3D visualizes output from MS3D and other MineSight products. Core functionality includes creating and manipulating 2D and 3D data, editing, querying, and plotting/display of all types of geology and mining data.

Jmineops is the fleet management software at the heart of the Jigsaw solution. It is the window into your mining operations, providing critical information – all updated in real- time – allowing dispatchers, administrators and maintenance personnel to seamlessly interact with the Jigsaw Jfleet, J2guidance and J3autonomous solutions.

The development and application of systems that can protect drivers and operators from collisions in busy surface mines, particularly where large haul trucks are interacting with smaller personnel vehicles, has been a major industry focus in recent years. Companies committed to safer surface mining turn to SAFEmine, the leader in Collision Avoidance and Fatigue Monitoring systems, delivering extensible solutions that save lives. Currently protecting more than 20,000 vehicles in over 50 mines worldwide, SAFEmine provides a complete range of advanced traffic safety solutions for surface mining and sets the benchmark for Collision Avoidance Systems (CAS). SAFEmine offers an array of products and services that include CAS, real-time full-fleet tracking, fatigue monitoring, systems to protect clean up equipment around heavy rotating machines, and sophisticated displays that integrate vital safety information intuitively in cabins. • 360° protection at any speed or visibility • Best proven and reliable Collision Avoidance System in surface mining • Upgradeable and customizable to mine’s requirements • Cost effective, can reduce downtime and improve SAFETY SAFEmine CAS LIVE REPORTING Track TrackingRadar ShovelAssist Reduce collision risks SafetyCentre FATIGUE MONITORING FatigueMonitor COLLISION AVOIDANCE Increase productivity Global Support productivity

Hexagon Mining is the only company to solve surface and underground challenges by integrating the world's best measurement solutions with proven technologies for planning, operations, and safety. We bring surveying, design, fleet management, production optimization, and collision avoidance together in a life-of-mine solution that connects people and processes. Out customers are safer, more productive, and can make sense of their data.

SHAPING SMART CHANGE FOR THE LIFE OF YOUR MINE Hexagon Mining is the only company to solve surface and underground challenges by integrating design, planning, and operations technologies for safer, more productive mines. By combining the experience, leadership, and expertise of MineSight, Leica Jigsaw, SmartMine UG, and SAFEmine, Hexagon Mining delivers an unprecedented portfolio of technologies.

Senior MineSight Specialist Ernesto Vivas and Luis Zozaya, Chief Engineer, Cobre del Mayo, discuss how the alignment of mine planning with operation has dramatically improved performance at the Piedras Verdes mine.

Alois Geierlehner, Director Business Development Geosystems, explains how Hexagon mine360 is connecting planning, operations, geodetic slope monitoring, surveying, UAV, and radar-based monitoring systems for a holistic view of a mine.

UAS Sales Manager, Bryan Baker, and Mine Planning Specialist, Johnny Lyons-Baral, explain the many advantages of using UAS and point clouds in blast optimization and general mining operations.

Safety Product Line Manager Cyrille Sauvain discusses how Hexagon Mining’s collision avoidance and fatigue monitoring technology is helping mines to respond to the ever-increasing demands for safety.

Episode Description: Hexagon Mining is combining integration and innovation to deliver real-time information that makes mines safer and more productive. EVP Technology and Innovation, Glenn Wylde explains the highlights.

Hexagon Mining is unique among technology providers in integrating solutions for planning, operations, and safety. President Hélio Samora discusses how the company is helping mines to prevail amid tough economic times.

A discussion of how to overcome resistance to organizational change.

Enrique Sánchez, Asesor Técnico Senior Grupo México, explains how the company has seen unprecedented levels of efficiency and control at its Toquepala mine in Peru by integrating fleet management with mine planning.

EVP Technology and Innovation, Glenn Wylde explains how Hexagon Mining is solving miners’ most complex problems - from autonomous mining to distributed computing - by adopting technology and innovating.

Times may be tough for the mining industry but President Hélio Samora explains how Hexagon Mining’s integrated approach to technology is relieving pressure on customers.

EVP of Technology and Innovation, Glenn Wylde, explains how Hexagon Mining is integrating planning, operations and safety technologies to solve surface and underground challenges.

Mines in the Asia-Pacific region are not alone in seeking more from their operations: more productivity, increased safety and a healthier bottom line. Hexagon Mining is uniquely positioned to solve these challenges in the region, explains Hexagon Mining President Hélio Samora.

African Barrick Gold (ABG) needed help to address rising energy costs and tightening profit margins at its North Mara mine in Tanzania. North Mara is a high-grade open pit gold mine with a life-of-mine estimated at 10 years, and the potential to process 8,000 tonnes of ore per day.

In 2013, Mexico’s Cobre del Mayo (CDM) was attempting to solve common, yet complex issues at its open-pit copper mine in southern Sonora, 21 kilometers from the town of Alamos. CDM produces grade-A copper cathode, supplied as refractory, and vein-type ore for processing into concentrate. The mine is a copper porphyry system, structurally controlled by shear faulting with mineralization stockwork, disseminated and variable depth ranging oxidation.

The Pueblo Viejo gold mine in the Dominican Republic is a joint venture between Barrick Gold and Gold Corp., which hold 60% and 40% ownership respectively. The mine is operated by Barrick Gold and 2013 was the mine’s first full year of production.

Pan American Silver subsidiary, Minera Corner Bay, operates the Alamo Dorado open pit silver mine in Sonora, Mexico. Commercial production began on April 1, 2007. Production from Alamo Dorado generates most of its revenue from silver with the remainder from gold.

The Greens Creek mine, owned and operated by Hecla Mining Co, produces gold, silver, lead and zinc from an underground mining operation on Admiralty Island, Alaska. Employees must travel a 19-kilometer, single-lane access road to access the mine site, which is shared with ore haulage and freight trucks. Hecla sought a simple and robust way to augment its radio call-out procedures to increase driver awareness of approaching traffic and improve safety on the access road.

Teck is Canada’s largest diversified resource company and the number-two exporter of seaborne steelmaking coal worldwide

Effective planning helps maintenance to provide consistently reliable equipment to operations.

Description of essential planning steps: establishing criteria to help determine which work should be planned: discussion of scheduling procedures.

Criteria for planning work; Planning steps; Scheduling procedures.

Situation – Today, many maintenance organizations are still not satisfied with the expensive, often complex and difficult to use information systems intended to help them control work. After many years problems still exist that should have been resolved long ago.

Discussion of why many fully-integrated industrial information systems fail to effectively support maintenance work control needs.

Maintenance supervisors have difficulty using work order system elements forcing them to use inadequate work control methods that provide neither control nor data required to develop essential information.

Information system elements are inadequate for some aspects of maintenance work control. But, maintenance organizations who have failed to define their programs and specify information needs have contributed to this problem.

A quality mine maintenance program is the best assurance that the 35% of operating costs typically spent on maintenance yields consistently reliable production equipment upon which mine performance depends. The accompanying Powerpoint presentation: Implementing the Plant/Mine Maintenance Management Program (93 slides) is provided as a professional courtesy to help evaluate your existing program or develop, document and implement a similar program. Additional Powerpoint presentations are available. A listing appears at the end of the presentation.

Increase Profit and Reduce Risk - We provide a managed solution including trainers, consultants and supervision at the level you require. Capabilities: Risk Management. Instructional Design and Curriculum Development, Training Center Design and Management, Training Needs and Performance Analysis, Staffing - all levels and all roles, part time or permanent, Continuous Improvement, Workforce Development Planning (for mines, regions and educational institutions)

Part 4 – Information Systems and Maintenance Work Control - Parts 1, 2 and 3 of this series established that many existing fully-integrated information systems do not provide adequate support of supervisor’s maintenance work control needs. Work order elements are too complex and time consuming for use in the ‘pressure-cooker’ working environment of maintenance supervisors. As a result many supervisors are using ineffective work control procedures that neither control work nor provide field data for required information. In turn, maintenance planners are compelled to prepare ‘official’ work order documents to capture missing data. Many planners are simply ‘work order administrators’ with no time left to plan. When management requires information, these planners may be ‘creating’ bogus information misleading management decision-makers. Since not all work requires planning, a simpler work order element for supervisors can meet their work control needs and also allow them to control all non-planned work. Information system problems are acknowledged by system developers but without being corrected. However, many maintenance organizations have contributed by not developing a well-defined maintenance programs and specifying their information needs. Instead, they have accepted and tried to use the generic information output of overly complex package systems. This ‘log jam’ requires corrective actions. An outstanding PC-based system that satisfies the supervisors work control requirements, returns planners to their full time planning tasks and creates essential information has been identified. The system developer’s introductory presentation was obtained and is attached.

The maintenance workload is the identification of the essential work carried out by maintenance. When properly identified it avoids confusion by clarifying the nature of required work and, most importantly, provides a direct means of establishing the correct size and craft composition of the workforce required to carry it out.

Reliability Centered Maintenance (RCM) is one of the most effective ways to improve the impact of preventive maintenance. While traditional preventive maintenance can avoid some premature failures, RCM adds advanced condition monitoring technologies to identify potential failures far more quickly and accurately while concurrently identifying root causes to eliminate or reduce their impact. A series of 6 phases examines the implementation of Reliability Centered Maintenance.

Part 2 provides an outline of the eight (8) steps recommended for the implementation of Reliability Centered Maintenance.

When mining maintenance requires improvement an evaluation is the essential first step of the improvement effort and a guarantee of its success. The evaluation avoids guessing at what needs to be improved, how and the priorities of corrective actions. The result is a realistic plan of action instead of confusion, frustration, disappointment and no improvement. Here’s how to get started.

Part 3 of Implementing RCM discusses Identifying Critical Equipment; Reliability and identification of failure patterns and Responses to general failure patterns.

Complete a free self-guided system review that provides you a customized report outlining simple, cost-effective ways to improve the operation of your dry chemical handling system.The System Health Check uses our expertise & data to help you take a proactive approach to identifying potential safety, reliability and process challenges before they become a problem.

Reliability Centered Maintenance identifies and applies maintenance responses to specific types of failures.

Updating the PM Program - RCM implementation will alter the nature of the PM program by changing the ‘detection’ processes. Inspections conducted on time-based intervals, for example, might give way to condition-based monitoring. Some time-based services might be supplemented with condition-based monitoring and some equipment might be subjected to redesign to better meet new requirements for reliability. Still other equipment especially of a non-critical nature might be allowed to run to failure. Explore these significant and worthwhile benefits.

Part 6 – Implementing Reliability Centered Maintenance describes the repair history capability and the use of analytical tools to support RCM implementation and ooperation.

The diversity of mining operations, experiences of personnel and numerous other factors may preclude standardizing mining maintenance terminology. However, a clarification of maintenance actions and procedures can improve common understanding and communication among all who perform maintenance, support it or depend on its effectiveness. Toward those objectives the following Mining Maintenance Terminology definitions are offered for your consideration. Any feedback can be incorporated into a revised document for subsequent publication. Contact: [email protected].

The primary purpose of posting Maintenance Terminology was to solicit feedback adding, modifying or removing the definitions listed. So far there have been numerous views and downloads and only one offer to add a definition. My 'best effort' at listing these definitions of common mining maintenance terminology warrants a closer look and some feedback. It seems important that mining maintenance establish that 'we do know what we are talking about.' And more importantly we inform those who rely on maintenance to know as well. Feedback to: [email protected]. A subsequent listing will incorporate your additions or modifications.

What kind of work does maintenance perform and how is it controlled?

UNDERSTANDING THE BACKLOG - It is not . . . “the work we ain’t done yet” . . . as many think. Rather, it is a valuable management tool enabling workforce size and craft composition to be determined and labor more effectively managed.

Three dimensional animations integrated into a process plant computer-based training program can greatly enhance trainee understanding of process equipment. This is an example of an animation used as part of an overall training program for a plant that uses an air-swept vertical roller mill. This type of mill is typically used in cement plants. Para ver este video en español, haga clic aquí.

Setting Maintenance Work Priorities - By setting maintenance work priorities, the relative importance of a single job in relationship to other jobs, operational needs, safety or equipment condition is established and a time period is assigned within which the work should be completed.

Joy Global rolls out JoySmart Solutions, integrated offerings delivering improved mine performance

This video provides an example of the content and structure of a Performance Associates International computer-based operator training program. In this video, we focus on the user experience of our eLearning module for operators in a gold mill grinding circuit. This example demonstrates the following program features: • Language toggle controls. • Interactive process flowsheets. • Process descriptions. • Principles of operation. • Workbook feature. • Equipment (SAG mill) 3D animation. • Process variables. • Control loops. • Interlocks. • Alarms. • Interactive plot plan. The grinding circuit is just one of 11 modules included in the complete plant operator training program. Each individual module covers the technical aspects of a specific plant area. The program also contains modules presenting basic introductions to many applicable unit operations and a variety of basic mechanical skills. Additionally, detailed maintenance training modules cover each significant piece of equipment in the plant. A comprehensive training component to develop supervisory skills is included as well. Building, running, and maintaining a new plant is a significant investment. A work-force well-trained from top to bottom is the best way to protect that investment by ensuring a successful start-up and continued operations at peak performance. If you are building a plant and preparing your operators and supervisors for start-up and operation, please stop and ask the question “what components of this training program do I NOT want my operations team to be thoroughly familiar with?”

Although many mines and processing plants have sophisticated maintenance cost information systems, cost control relies ultimately on management actions based on the information such systems generate. A systematic management approach to solving problems and implementing solutions is the key to effective maintenance cost control

Effective plant-specific computer-based training (CBT) used in a formal training program can make the difference between a successful start-up and a failure. Or, in the case of an existing plant, it can make a huge difference in the effectiveness of operating results—particularly if turnover of experienced personnel is a factor. Once the plant process design and control strategies have been established, equipment has been ordered, and the plant is either operating or under construction, the only major variable affecting success is the capability of plant operating personnel. It is essential that the myriad details concerning plant operation are documented in a comprehensive CBT system suitable for training the non-technical personnel who will operate the plant.

In this training module, Performance Associates International (PAI) covers the characteristics of a gyratory crusher that’s designed to be the first stage in the size reduction of run-of-mine ore. A gyratory crusher receives ore from a mine and crushes the ore between a gyrating main shaft and stationary liners called concaves. This module explains the gyratory crusher’s principle of operation and provides detailed descriptions of the major components and the role that each component plays in its operation. You'll learn how the drive system operates, the details of the dust sealing system, the importance of the various lubrication systems, and the two functions of the main shaft positioning system, or MPS. We’ll also explain the operation of the balance cylinders and how they’re designed to prevent oversize boulders from causing damage. We’ll also cover the apron feeder, which conveys the crushed ore from the crusher to a downstream discharge conveyor belt. The principle of operation and detailed descriptions of the components of the apron feeder—including the drive chains, pans, rollers, and an electric or hydraulic motor—are illustrated. This is one of many plant area modules that is covered in a typical PAI operations training module.

Determination of equipment availability levels to meet production targets is strongly influenced by the quality of maintenance support. But for maintenance to deliver reliable equipment and operations to meet production targets, mutual understanding of the elements that impact availability is essential. Comments on the illustration are most welcome.

What would it mean to your process if the variation in your key process variables could be cut in half? For example, consider greatly reduced variation in: • Leach circuit pH. • Thickener flocculant concentration. • CIL circuit cyanide concentration. • Cyclone feed density. Do your operators know if variation is random or non-random? If your operators were more familiar with the process control methodology, would it make a difference? What would be the result if your operators could troubleshoot and optimize each process control loop? At Performance Associates International (PAI) we believe that if the process variables in the plant are controlled at or very near their individual target ranges, the plant should be operating at near optimal efficiency. This translates into the lowest operating cost per unit production. This white paper describes how PAI approaches this component of training for your specific plant. We train on your process variables, their target ranges, the method of controlling those process variables, as well as the impact on the process if the process variables are not properly controlled.

Far too often, natural resource companies start up new plants without a properly trained operations and maintenance team. The results can be disastrous for both safety and revenue. Obviously the ultimate objective is a plant that operates in a safe and profitable manner. In most cases, the pre-start-up safety training is satisfactory, resulting in few if any accidents during start-up and ongoing operations. However, many plants drop the ball when it comes to properly training operations and maintenance personnel. The payback on a properly executed training program far outweighs the cost. If you are going to budget for high-quality engineering, efficient procurement, and experienced and proven construction management (including commissioning), why leave training open to chance? Performance Associates International (PAI) developed an extensive operations and maintenance training program for Torex Gold’s El Limón-Guajes project in the state of Guerrero, Mexico. In 2015, PAI industry training specialists traveled to the project site to carry out the training for Torex Gold employees in anticipation of plant start-up and gold production. The venture was a “massive success,” according to Nelson Bodnarchuk, Director, Operational Systems. This video tells the story of that success, including generous feedback from the executive officers at Torex recognizing our role in the partnership.

These recommended duties and responsibilities of key maintenance personnel provide guidelines for efficient maintenance interactions and interdepartmental cooperation that can enhance the overall maintenance performance,

Con demasiada frecuencia, las compañías de recursos naturales ponen en marcha plantas nuevas sin contar con un equipo de operaciones y mantenimiento debidamente capacitado. El resultado puede ser desastroso tanto en términos de seguridad como de ingresos. Obviamente el objetivo fundamental es una planta que funciona de forma segura y rentable. En la mayoría de los casos, la capacitación sobre seguridad que se da antes del arranque de la planta es satisfactoria, resultando en pocos accidentes (o ninguno) durante la puesta en marcha y operaciones subsecuentes. Sin embargo, muchas plantas son negligentes cuando se trata de la buena capacitación de su personal de operaciones y mantenimiento. Un programa de capacitación bien ejecutado compensa con creces los costos de ejecución del mismo. Si se va a presupuestar una ingeniería de alta calidad, un proceso de adquisición eficiente y una gestión de construcción experimentada y comprobada (incluyendo el comisionamiento), ¿por qué dejar a la suerte la capacitación? Performance Associates International (PAI) desarrolló un programa de capacitación por computadora comprensivo, el cual abarca operaciones y mantenimiento, para su planta de oro El Limón-Guajes en el estado de Guerrero, México. En el 2015, los especialistas de capacitación industrial de PAI viajaron al lugar del proyecto para entrenar a los empleados de Torex Gold en anticipación de la puesta de marcha de la planta y la producción de oro. El emprendimiento fue un “éxito masivo,” según Nelson Bodnarchuk, Director, Sistemas Operacionales. Este video cuenta la historia de ese éxito, incluyendo comentarios generosos de los oficiales ejecutivos de Torex, quienes reconocen nuestro papel en la colaboración.

The availability of skilled mining workers is a common struggle in many countries throughout the world, impacting mining productivity, safety and ultimately profitability. Many countries are forecasting dire shortages in the coming years due to unskilled talent pools, an aging workforce and increased mining production. The development of training programs is a key focus for governments, mines and educational institutions. In support of this industry challenge, Immersive Technologies’ solutions have proven to be vital at numerous training centers around the world. In this case study one customer shows how the introduction of a simulation based training center accelerated operator learning and retention. Over the past five years this type of training center has been on the rise for Immersive Technologies. More case studies are available by emailing [email protected]

What are your operators really costing you? Operator skill and behavior directly affects site safety, tire life, bucket fill, machine availability, fuel usage, cycle times and machines repair & maintenance costs. Successfully managing each of these aspects can be the difference between a mine that is profitable and one that is not. Immersive Technologies can show you the financial gain of improving each of these through Operator Optimization on your mine. We’ve done it many times before. We’re yet to find a mine that has no opportunity for significant financial gain.

Simulation based operator training has been successfully applied to a range of diverse industries where high risk and high costs are everyday issues requiring smart solutions. Whether piloting a plane or launching a space shuttle, simulation training has been proven to dramatically reduce risk, cost, unscheduled maintenance, increase trainer effectiveness and efficiency while maximizing productivity. Within the often hazardous mining industry, simulation training has quickly gained recognition as a significant method of increasing site safety and profitability through improved operator skill and knowledge. Simulators provide operators a safe environment to learn and practice their skills while allowing the operator to practice for a range of possible emergency situations. Many of these situations are too dangerous, too difficult or too expensive to test in an actual mine. Operators can also be shown and assessed for the proper operating technique much more quickly and accurately than the traditional in machine approach. Focus on improving operator technique with Immersive Technologies’ simulators has delivered proven results including longer tire life, reduced spot time, reduced brake abuse, improvements in fuel use, reduction in engine overspeeds and more. Simulator training allows operators to be shown and assessed without the need to borrow machines from production. This allows new operators to practice many skills before being placed into a production circuit. Because operators are consistently shown and assessed on the proper operator techniques they have a better understanding and knowledge of the real machine. Following Immersive Technologies release of the world’s first mining dump truck simulator in 1998, their customer results, support network, machine range, global mining footprint, level of realism and OEM endorsements are without equal in the industry. Highlighting the benefits of simulation training, four leading Original Equipment Manufacturers, Caterpillar, Hitachi, Komatsu and Liebherr have chosen to exclusively sign technical information licensing agreements with Immersive Technologies, providing access to proprietary technical information necessary to accurately replicate the operation of their mining equipment. After significant supplier evaluation each major OEM has chosen to exclusively recommend Immersive Technologies' Advanced Equipment Simulators. This unprecedented support and commitment from the OEM's has helped to firmly entrench Immersive Technologies' Simulator technology as the industry leader. This provides customers the comfort of knowing they are investing wisely in a proven and accepted technology that is here to stay. As the world’s largest supplier of mining equipment simulators, Immersive Technologies’ has a customer base that includes many of the world’s leading mining operations, mining contractors, training schools and original equipment manufacturers. Widely recognized as the global industry standard, Immersive Technologies’ has extensive experience in delivering complete training solutions to the mining industry with measurable safety and business improvement outcomes. Immersive Technologies has worked closely with thousands of mining training professionals, managers, and executives to deliver comprehensive solutions that have been proven to improve safety and mine profitability.

Any maintenance improvement effort should be initiated with an evaluation to identify and prioritize essential improvement needs. Comparing current performance against proven standards is an effective means of evaluating to establishing a realistic improvement plan and guide the improvement effort.

There are no world class maintenance organizations. Rather, there are ‘world class’ mining organizations that include a world class maintenance organization. Maintenance, by itself, is a service-provider. When that service is exceptional, it is made that way because maintenance is operating in a mining environment that requires it to be exceptional. Mining managers will have created a working environment in which maintenance can be exceptional. They have caused operations to accept responsibility for the effect utilization of maintenance services and staff departments like warehousing or purchasing to provide exceptional service because it is expected of them. World class status is only achieved when there is a total operation effort.

Successful implementation of Reliability centered maintenance (RCM) creates circumstances that sharply increase the equipment problem detection capabilities of preventive maintenance. In turn, gains in the ability to plan more work help maintenance to deliver consistently reliable production equipment for its mining operation.

The authors describe the application of remote isolation systems in mining industry conveyance systems and offers case study details where these systems have been installed.

Education – A Counterbalance to the Mining Maintenance Challenge. The already difficult circumstances of mining maintenance are compounded by remote locations, indigenous workforces, recruitment of management personnel and a whole range of difficulties, some unexpected. Many of these adverse circumstances can be offset by educating the mining workforce on how they can help to make maintenance more effective. Please see the Mining Maintenance Management Course.

The maintenance supervisor holds the most difficult job in mining. Don’t think so? Then consider his daily situation.

Consider the impact these five educational steps could have to help improve maintenance performance. Initially, clarify internal maintenance actions. Then specify help needed from other departments. Finally, secure the dedicated overall direction from mine management in a mine-wide coordinated maintenance effort

Solving the Mystery of Improving Maintenance Maintenance often represents over 35% of total mine operating costs. Yet, little is known by the general mining population of the details of what maintenance does, how they do it and the help, support and cooperation they require. Many see maintenance as a ‘closed book.’ Herein are both the problem and the solution. Maintenance has done little to explain what they do, how they do it and specify the help that they need.

Mining is unique among all industries as are the challenges of maintaining its equipment. Successful maintenance will require fully-coordinated help from all departments and knowledgeable, dedicated management oversight. Effective training can help to meet these requirements. Un fortunately, public seminars on maintenance management are seldom mining-specific and are usually generic. Little that is useful can be learned from these generalizations or from non-mining attendees. Attendance fees and travel expenses can be prohibitive. Attendance from remote mining locations is seldom possible. These remote workforces can include local recruits unfamiliar with mining and are often staffed with ex-pats with widely diverse backgrounds and experiences. Training can enable them to perform consistently as a reliable team. All of these training needs can be met by the Mining Maintenance Management Course specifically designed for on-site training conducted by your own personnel.

No Maintenance Program – Major Omission Attention Mine Managers – If maintenance does not have a program parallel to the one described in this article, don’t expect them to be able to deliver consistently reliable production equipment. Here is how to correct that situation. See an important notice at the end of the article.

A maintenance program that prescribes who does what, how when and why is the primary necessity for effective maintenance. Without it you are wasting your time. Here's the proof.

Maintenance Planning Essentials Please review the PowerPoint presentation to learn the essential, proven planning techniques that ensure the significant benefits of well-planned work are achieved. Note especially the illustrative diagrams, informative captions and the detailed instructor’s notes that ensure effective training.

The mining operation that understands who does what about performing or supporting maintenance, how, when and why can meet the objective of providing consistently reliable production equpment. A well informed workforce confident in all aspects of achieving effective maintenance guarantees this reality. The reality is the development, documentation, implementation and operation of a proven mine maintenance management program.

Maintenance in Transition – The Journey to World Class Maintenance is the classic text book on every phase of maintenance management.

Learn what World Class mining organizations do to make maintenance planning more efficient, deliver reliable production equipment, reduce cost and help ensure mine profitability. Implementation of these 10 actions can have a direct, positive impact on maximizing maintenance performance. A must read for all mining and maintenance managers whose objectives include improving maintenance.

The utilization of professional training materials in the conduct of on-site maintenance management training has many advantages. Training can accommodate the availability of key personnel to avoid conflicts with operating schedules. As many personnel as necessary can be trained, singly or in logical organizational groups. Personnel from several departments can be trained together to clarify interdepartmental roles and actions. Presentations can be repeated for new personnel or those assigned new responsibilities. Individuals can train themselves. Training needs at remote mining locations are met avoiding expensive attendance fees and travel expenses to distant venues. Training solutions and recommendations are based on actual, realistic and proven situations unique and directly applicable to the mining industry.

Browse the directory for Haulage & Loading 2017. This includes complete exhibitor list and contact information along with the technical program for the conference.

A maintenance organization was found to be planning only 21% of all work. Study revealed that most equipment deficiencies were being discovered just before failure. Major jobs that required detailed planning were being attempted as unplanned work. As such, they cost too much, took much longer to complete, were hurried and often failed again prematurely. How was this situation corrected?

I have attached a PowerPoint (PPT) presentation on how to implementing a Mine Maintenance Management Program. But before you study it please understand that superior maintenance performance is built on three conditions: 1 - Maintenance proficiency – Maintenance personnel from manager to worker are proficient in all aspects of management, control and work execution. 2 - Knowledgeable support – All mining departments understand the help needed to make maintenance successful and provide it. 3 - Strategic direction – Mine managers assign mutually–supporting departmental objectives, provide policies to guide interdepartmental actions and verify performance. The one proven answer that meets these conditions is a quality maintenance program. That program must spell out who does what, how, when and why. These guidelines must be applied to the nine essential maintenance management phases: How to (1) Request or (2) Identify work, (3) Classify it to determine the best reaction, then how to (4) Plan, (5) Schedule, (6) Assign, (7) Control and (8) Measure the resulting work and finally, (9) Assess accomplishments against goals such as performance standards and budgets. All personnel in maintenance as well as those who interact with maintenance must be included in the program since every maintenance action requires a supporting or cooperative interdepartmental reaction. Just as the maintenance planner follows specific planning procedures, so must the purchasing agent who orders major component replacements for the job the planner is organizing. After 44 years as a mining maintenance management consulting in all types of mining operations, I can confidently state that the absence of a quality program will preclude meeting these three conditions and frustrate all efforts to achieve superior maintenance performance.

Mining Maintenance Management Course - The Course includes 22 essential maintenance management topics presented in a logical, straightforward PowerPoint format. Strategies, techniques, methodologies, technologies and procedures are accompanied by step-by-step instructions, illustrations, case studies and detailed instructor’s notes.

This paper outlines the experience of one global cement producer that embarked on site surveys and studies to achieve arc flash safety compliance at 13 cement plants in the U.S. and Canada.

The purpose of this paper is to review a case study of a successful energy project at the ArcelorMittal Burns Harbor facility involving the addition of five new adjustable frequency drives (AFDs) used to regulate flow of the high-volume water spray system for the runout table (ROT). The paper will outline 1) processes used in justifying new technology updates, 2) mill alignment with the serving electric utility to leverage energy credits, 3) equipment selection and installation and 4) metrics used to demonstrate the project delivered the desired payback.

Download PowerPoint instructions - How to Implement a Maintenance program.

The Mining Maintenance Management Course is ideal for training maintenance personnel on the procedures, techniques, strategies and methodologies required to manage maintenance effectively. While maintenance personnel are the primary audience, staff organizations and operations will learn how to focus their support and cooperative efforts to enhance maintenance performance. Mining managers will appreciate recommended policies and key indices to guide and monitor the overall maintenance effort. The overall course objective is the development of a cohesive, efficient team from manager to worker to meet the unique maintenance requirements of the mining industry.

The Elusive Qwest for World Class Maintenance - ‘Seat of the Pants’ Maintenance Isn’t Good Enough - A major deficiency of too many mining operations and the explanation of most maintenance problems is no program. As a result, maintenance personnel who are to carry it out or support it (like purchasing, warehousing and operations) are confused and uncertain about how to help. Mine managers are frustrated and impatient, expecting that maintenance should, by now, know what they are supposed to do and how. Too many assumptions have been made starting with the mine manager who should have said, "I want a logical, well-defined program about maintenance that fits our operating plan and I want all mine personnel to understand it, support it and make it work." To those mining operations and their maintenance departments who insist they know what to do, have them prove it with a well-documented program. Many can’t.

A maintenance organization was found to be planning only 21% of all work. Study revealed that most equipment deficiencies were being discovered just before failure. Major jobs that required detailed planning were being attempted as unplanned work. As such, they cost too much, took much longer to complete, were hurried and often failed again prematurely. Read how this situation was corrected.

Here are some of the maintenance planning/scheduling questions that require resolution if this activity is to be carried out efficiently.

Significant work control problems are needlessly created when there are no criteria for determining which maintenance work requires planning.

Determine production utilization required to determine minimum equipment availability. Comments welcome.

How to Utilize Maintenance Planners Effectively Don’t waste this valuable resource Paul D. Tomlingson A Key Player - Maintenance planners are utilized in larger organizations where there is considerable major work requiring detailed and advance preparation before the work can be scheduled. Smaller organizations still have a need for planning but, the task is often carried out by supervisors or team members. For those organizations using planners, it is important to establish what the planner should do, how it is done and what tools are required to do it well.

Too often training is done “for the sake of it” or only to fulfill a compliance requirement. In reality the biggest return on investment from training equipment operators is achieved by targeting actual performance variance identified through data including fleet management system data. Performance variance in production, machine abuse and safety costs an average mine millions of dollars per year.

Establishing criteria for determining which maintenance work requires planning can improve work control efficiency.

Ramp trials of the MacLean BT3 battery electric boom truck in Canada - Switching out diesel fuel for battery electricity on mobile equipment in underground mining is as much of a user experience exercise as it is an engineering exercise.

This underground nickel mine in the Midwest United States is relatively young with only a few years of production blasting. The operation is employing a sublevel stope mining technique. The operator purchases Dyno TITAN® RU emulsion and electronic detonators for blasting. The customer was experiencing poor blast results over a substantial period of time. When the customer first contacted DynoConsult® for assistance, the concern was the under-breaking of the ore which left valuable material along the ribs. At that time the mine engineers were looking for guidance on the delay times they should be using to improve the recovery of ore. During the site visit by DynoConsult, it was also discovered that there were a few instances of benches and bridges being left in the stope after mucking. In one stope it was estimated that over $1 million worth of ore was left unrecoverable in the stope. It was also revealed during the site visit that there were issues related to tight digging of the muckpile even though the fragmentation was adequate.

Sometimes a turning point can only be seen clearly in hindsight. Such is the case for the mine of the future as we begin 2018, coming out of a 2017 where major mining companies continued to demonstrate capital spending austerity and focus on debt reduction. All the while, there were growing signals that digitalization, electrification and automation were all gaining momentum, even though actual examples of minesite implementations could as of yet, still be counted on one hand. MacLean took the opportunity that industry downturn presented over the past several years to focus intensely on three key product development ventures – first and foremost, the battery electrification of our entire fleet, which will be complete by the end of 2018; second, the successful introduction of face bolting as a feature on our 975 Omnia bolter; and, third, the launch of the latest addition to our utility vehicle product line – the LR3 Boom Lift for heavy load and high reach applications. The past year was one where for the first time we had a fleet of battery electric vehicles working underground, allowing us the ability to validate our performance and total cost of ownership (TCO) models with real-world data, while at the same time continuing to build out our EV offer across the product lines. Looking forward, as we work hard to fully electrify our fleet of ground support, ore flow/secondary reduction, and utility vehicles, we’re keenly aware that electrification is but one step in the ongoing mechanization of underground mining, a transition to the mine of the future that will be increasingly efficient through digitalization and automation that will increase production and reduce costs.

This maintenance management course is unique to the mining industry. Its objective is to improve maintenance through the education of personnel at all levels of the mining organization. It represents over 40 years of direct, world-wide mining maintenance consulting experiences to provide proven, useful and practical improvement guidelines. Topics are logically arranged and emphasize the interdependence of maintenance actions, essential interdepartmental coordination and knowledgeable management guidance. The accompanying textbook reinforces the course and stands alone as a classic source on mining maintenance management to guide achievement of World-Class status. Inquires: [email protected]. Paul D. Tomlingson, Mining Maintenance Consultant Denver, Colorado USA Member, Society of Mining, Metallurgy ad Exploration (SME)

Drones have exploded in popularity thanks to their versatility and the growing accessibility of the devices. Flown carelessly, drones can be dangerous. While drones work to keep employees safe and out of dangerous environments, it's important to be aware of the regulations enforced by the Federal Aviation Administration. Check out our Drone Regulation Guide published in Occupations Health & Safety to review a couple of important considerations in maintaining safe and legal flying practices.

A true service provider is called upon to bring all of their tools, knowledge, and expertise in times of crisis. We provide our clients with confidence in their data, and go above and beyond to serve them and work with them to solve critical problems. One of our clients was facing a serious problem when an underground tunnel was in grave danger of collapsing or causing a major flood. Read our case study to find out how we used the right tool for the job and found a solution to their problem.

Learn about Telsmith's annual Technica Trainings. Training focuses on Telsmith T-Series and SBS Cone Crushers, Iron Giant and D-Style Jaw Crushers and Inclined Vibrating Screen products.

Drone technology is still relatively new, but the adoption of drones is revolutionizing the way we work in countless industries. The aggregate industry rarely leaps at the latest and greatest technologies, preferring to stick with known commodities, but those who incorporate drones will discover that they have the potential to create a far safer and more efficient job site. First published in Cement Americas Spring Edition 2018, this article discusses 3 steps to follow to incorporate drone usage into your workflow.

This guide describes our recommended best practices for setting, maintaining, and capturing Ground Control Points suitable for creating 3D maps using drones. We've included tips for GCP placement, as well as how to properly maintain your GCPs to ensure you are establishing an accurate position of data.

The amount you pay for your measurement is not your only cost when it comes to inventory. In the industry, we talk about what it costs to measure your inventory, but rarely do we discuss the cost of not measuring your inventory. Cutting costs by rarely measuring inventory could actually be costing your business more money. We invite you to download our article on the costs associated with not measuring your inventory for more information.

Firmatek has been measuring stockpiles and helping the Aggregate Mining Industry manage its inventory for almost 30 years. The industry has used a variety of different technology over the years. From wheel and tape, to drone solutions, Aggregate Mining companies have continued to develop innovative solutions for measuring inventory. With each evolution in the technology, there have been improvements in everything from accuracy, to safety, to management systems. Let’s take a look back at how we got to where we are today.

Data is everything, but gathering it can be a challenge. There are several factors that go into choosing the right technology for your site. LIDAR and drone technology are both effective data collection methods, so how do you know which method is the best tool for the job? For aggregate producers, there are a few key questions you should ask when deciding which technology is best for a particular job. Download our article to learn more about the 4 questions you should keep in mind when choosing between LiDAR, drone technology, or both.

Planners are most effective when they plan the right work. Here are some recommendations for determining which work should be planned in your organization.

Planning and scheduling maintenance work should follow specific procedures. Here are some suggested guidelines.

Firmatek's strategic Drone Program addresses the complex needs of clients and delivers the same precise measurements and data analytics that our customers have come to know and trust. Our drone solutions are simple, fast, and accurate. Simply fly the drone on your site, and upload the data to our client portal for processing. Firmatek doesn't stop there, we make sure you understand what the data is saying so you can be confident in the decisions you make for your operation. We invite you to watch our Drone Program video for more information. Get started with Firmatek Drone Solutions today!

Manual mapping methods are expensive, time consuming, and dangerous. Firmatek is breaking that paradigm using drones to simplify the mapping process. We use drones to collect mapping data from our client's sites and integrate technology into our service offering. Download our article to learn how.

A lot can happen in a month or quarter on your site, making it difficult to prepare for your month end inventories. Firmatek’s Drone Solution allows you to fly your sites and then upload the data to our team for processing. This gives you the flexibility you need to capture data when you need it. With this in mind, we've developed three tips to remember when preparing for your month end inventories. Download our article to learn more!

Technology is adding unparalleled value to the mining and aggregate industries. Executives and plant managers are able to access more information than ever before, allowing them to make better, more informed business decisions. However, technology adoption in mining could frighten many employees in the industry for various reasons. To help ease their fears, we've developed 4 things to keep in mind. Download our article to learn more!

Technology has made business operations more seamless, but in order to understand exactly what customers need, you have to spend time with them and get to know their business. It’s more than a sales pitch — we like to partner with our customers to create the best technology solution. Despite the constant stream of technological advancements we enjoy, the human element isn’t going out of style. If your company is looking to stand out from the crowd, incorporating the human element into your company-wide strategy will help you reach your full industry potential. Download our article for strategies on how to maintain a personal touch in your tech company. 

Training is a make or break customer satisfaction opportunity. If not executed well, it can actually chase your clients away. It's our job to make sure our clients are prepared and equipped to capture great data. With this in mind, building a strong training program has been a key focus this year at Firmatek. Our Chief Drone Officer, Andrew Maximow, identifies 3 key take-aways that he believes make training programs great. Download his article to learn more.

Each individual will require more than 3 million pounds of minerals, metals and fuel during his or her lifetime, meaning companies must optimize to meet increased demand. Big data can help achieve that goal, but only if it's used correctly. Because data is being collected more frequently, it's more important than ever for everyone to understand the basics of data collection, analysis, and delivery. The best way to do this is by forming an accurate  picture of the end-to-end process. Download our published article to learn more. 

In an industry where technology is constantly evolving, you can’t just listen to what everyone is saying. When there’s a new drone or app introduced every few weeks, how can you keep up and separate the truth from the hype? In our latest blog, Chief Drone Officer Andrew Maximow debunks 3 popular myths about drones in the commercial & industrial space. Download his full article here!

Turner Mining Group continues to embrace new technology to increase efficiency and keep their employees safe. Drones have had a big impact on both of these factors. From billing reconciliation to safety, adopting Firmatek’s Drone Solutions across Turner Mining's nationwide organization has helped them improve efficiencies in a number of areas. Download our case study to learn how drone solutions can help improve your operations.

Transform your site data into business intelligence. Conducting inventory measurements on a monthly basis gives you key insights about your operation. The measurement itself is just data, but when you turn the data into insights, you're building your level of business intelligence. This allows you to manage and improve your overall operation. Download our article to learn more about the 3 Reasons to Conduct Monthly Inventories and how you can improve your operation.

Let's face it: Pipeline planning and upkeep require a huge investment of capital. Technology is taking pipeline construction and maintenance to another level. Ignoring the benefits of tech is no longer an option. If you want to keep up with the competition and improve safety, efficiency, and profits, you have to jump on board and make the most of what's available. Download our resource to learn more.

Are you a DIY-er? Or do you prefer hiring a full-service provider? The choice between the two comes down to what you value most: time, cost, or the experience you want to have. At Firmatek, we believe that clients deserve a tailored solution and we work with them to determine which option on the spectrum of full service to partial DIY makes sense for them. We work with clients to uncover what value choices are right for them. Download our article to find out where your business falls on the DIY spectrum. p.p1 {margin: 0.0px 0.0px 0.0px 0.0px; font: 12.0px Lato}

Moving from using traditional surveying techniques to using drones for aerial data capture can increase productivity as much as 200%.  You can deliver the data you have always produced for your customers quicker and take on new projects that were too complex or hazardous before.With Firmatek’s Data Analysis and Reporting Platform, you can quickly fly a site and process the data in hours, providing a fast, cost-effective way to perform surveys. Our platform turns your drone captured aerial imagery into high precision 2D maps and 3D models, reducing expensive and time-consuming field work, while expediting the output of reporting and analytics, while providing you with survey-grade accuracy, custom reporting and reliable analytics designed for surveying and mapping.

Once upon a time, decision makers in the aggregates industry had to rely on guesswork to figure out whether they could meet a client need. Fast-forward to today, and drone technology has taken much of the guesswork out of the equation. Plus, mines are safer because data collectors are spending less time in the field.As drone tech continues to improve, there will be fewer and fewer reasons for decision makers not to incorporate drones. In the aggregates industry, it's imperative that executives begin to prepare even their most tech-challenged employees for a drone-filled future. Download our article, published in Rock Products, to learn about four tips that can help you get started. 

At Firmatek, we love technology. Who wouldn't want to have cool drones, lasers, and software? But cool tech isn't what makes our clients' operations more successful. It's the insights we provide from the information tech gathers. We often see clients start with the "what" when they need to be looking at the "why." Why do you want to use technology? How will it help your business? We use tech to give you more than just another data point or inventory volume. We give you insights that help you increase your business intelligence. Download our resource to learn more about business intelligence.

We consistently tell our clients one thing: you can't manage it if you can't measure it. The increased demand for data analysis and use of drones for 3D mapping has prompted more questions around additional case uses for drones. And in 2019, we see this trend continuing. As the "early majority" adopters in the commercial/enterprise drone industry climb up the "slope of enlightenment", there is a need for different ways to measure its growth beyond the number Part 107 license and drones being deployed. For us the key to growth is in the demand for data analytics. This demand, in turn, will further drive the supply of drones and Part 107 pilots. How does Firmatek plan to facilitate demand and drive growth in the drone industry? Download our resource from Chief Drone Officer, Andrew Maximow, to learn more.

We're always looking for new ways to help clients solve problems, increase productivity, reduce waste, and improve safety. So when our client approached us about finding a better way to identify joint sets, we created this deliverable with a services-led, technology enabled approach. Download our resource to learn more about the importance of identifying joint sets and how they effect operational efficiency and safety.

We talk a lot about providing insights to our clients and equipping them with business intelligence. Researching and testing new technology helps ensure we can do that. With this in mind, we recently had a field tech training day where we introduced our team to two new members of our drone fleet: the FireFLY 6 Pro and the DJI Phantom 4 RTK. Training is an important part of setting up our team and our clients for success. It is critical for our team to have the skills to succeed. If we just give them the tool, but don’t give them knowledge to use it, we are not going to be successful. We give them the knowledge to raise the bar. Download our resource to learn more about what our team is saying about our new drone technology!

Stockpile measurements are an integral part of running a successful aggregates business. Operating efficiency and profits depend on stockpile measurements, yet many aggregates operations are guilty of making numerous common mistakes. Stockpile measurements aren’t 100 percent perfect, but you should focus on making accuracy one of your top priorities. With a more refined picture of your stockpiles, you can base decisions on sound data instead of deceptive estimates, improving efficiency and boosting profit margins. To solve some of the most common measurement problems, there are a few strategies to keep in mind. Download our resource to learn more! 

We frequently get asked about the drones or UAVs that we use. What is the best drone? Why do you use such-and-such vendor? Utilizing the best technology available helps ensure that we can equip our clients with the business intelligence that they need to improve their operations. A one-size-fits-all solution in our industry isn’t practical, so we work with our clients to determine the best tool for precise and efficient data collection. Check out part one of Andrew Maximow's article series, Guide to Drone, to learn more about how we choose the right tool for the job. hashtag

What if there was a cost-effective way to get accurate, timely, and frequent data? Drone technology is changing the game. Tech has transformed the way you manage your dirt-moving operation and is drastically improving efficiencies. New tech can be hard to embrace and hard to implement. That's why we believe in supporting our clients through that transition process. It is worth the challenge of a new process to have the information you need to improve your operation. Download our resource to learn more!

Geospatial mapping is becoming a game-changer in the quality of the construction process. The construction industry is continually evolving, trying to find the best ways to maximize their profits and ensure efficiency. Cutting-edge drone technology has been a key influence working towards goals of better documentation; project management and inspections; and designing, planning, and estimating. Download our resource to learn more about the advantages of utilizing geospatial mapping data in your operation.

Does Firmatek hire drone pilots? The short answer is no. Providing key insights is our WHY. Collecting data, whether with drones or other tools, is just the tip of the iceberg of WHAT we do. Because of this, when we hire we look for skill sets beyond Part 107. We hire people who speak our client's language— mining, geology, construction, energy, and civil engineering. Andrew Maximow provides an in-depth explanation on our blog. Check it out here!

While drones are widely used for collecting amazing photos and videos, technology is evolving rapidly to collect and analyze more data. Industries that deploy drone tech discover new possibilities. Firmatek is helping clients in several industries get started with data, build use-cases, and deliver insights via more quantitative and qualitative data analytics. In the first blog of our Guide to Drone Series, we discussed the criteria we use to select drone/UAV platforms. In this article, we take a closer look at specific use-cases and the types of data they provide. Download our resource to learn more.

Many people look to implement drones into their operation and only go as far as to think about the data they are receiving. At Firmatek, we enable our clients by giving them more than just a number. We believe in using the right tool for the right job, so we work with our clients to provide a solution that works for them. Sometimes that means we do everything from collecting the data to analyzing it and providing analysis and results. Other times, we put a drone in the hands of our clients and they collect the data and we do the analysis; often, we do a combination of both. Our clients take the analysis we provide and use it to elevate their business intelligence and improve their efficiencies. That's why Turner Mining Group chooses our drone solutions. Download our resource to learn more about our Q&A with Turner Mining Group at the AEC Next conference this week.

In an industry that’s flooded with new and improved tools and software systems, we help our clients by providing key insights and custom solutions. Serving our industry to the best of our ability requires us to act as trusted advisors. We start by suggesting the right tool for the job. In part three of our Guide to Drone series, Steele Olsen, Geospatial Field Technician, highlights some specific UAV platforms that are currently in-use at Firmatek and discusses why they fit well within our clients’ operations. Download our resource to learn more about the tools we use and why!

In many mine and plant operations, safety is looked upon as an extra layer of special attention placed above the operations management layer. But safety awareness must be built into the detailed operations and maintenance training on the equipment as well as on the process itself.  

Performance Associates (PAI) delivered a jaw crusher introductory maintenance manual and animation to Northern Star Resources, Ltd.—Kanowna Belle Project in Western Australia on June 7, 2019. The animation provides a narrative description of the jaw crusher’s location in the process, its function, components, and maintenance requirements. With this delivery, PAI successfully met Northern Star Resources’ need for an animation that could introduce new maintenance personnel to the Kanowna Belle jaw crusher in a dynamic visual context. The narrated animation replaced the standard text and graphics in the description section of the equipment maintenance computer-based training (CBT) module. The descriptive text was adapted to a narrative form. Multimedia specialists used engineering drawings and photographs to create models of the equipment and animate the modeled images to illustrate the key concepts and components in concert with the narration.

As many industries are adopting drone technology across their entire organizations, it is important to learn from our collective successes, mistakes, and key findings. Regardless of your industry, there are many similarities in implementing a drone program across your organization.Building an Enterprise Drone Program requires first seeking to understand why you want it, what success looks like, and how you want to build it. Building a successful Enterprise Drone Program is a large task. But when done well, the impact on your business can be significant. You will gain the business intelligence that you need to make your operations more efficient.Download our white paper to learn more about successfully building and implementing your enterprise drone program.

Excellence in Mining, Process Plant, Maintenance, and Safety Training  Performance Associates International, Inc. (PAI) is the world leader in online and on-site training for the mining industry. We provide organizations with a single source for assessments, skills training, continuing education, safety training and compliance mandates, and more. Our first-class content guides your staff to gain the critical knowledge they need to work safely and efficiently today.  Our proven, leading-edge industrial training programs improve performance in existing operations and ensure success during the start-up of new operations. Our training programs have saved companies millions in personnel accident prevention, production loss, and equipment damage. We partner with our customers and consult collaboratively to provide the analysis and content development to meet your needs.  Services PAI Offers  Plant Operator Training Our three-tier concept for effective plant operator training starts with fundamental knowledge and progresses to plant-specific concepts that are reinforced through detailed animations and interactive simulations.  Maintenance Training We custom build state-of-the-art maintenance training programs using exploded graphics, explanatory text, detailed procedures, and management systems.  Mobile Equipment Operator Training Our first-class training program focuses on operator controls and indicators, safety, and performance optimization. It also includes operating, emergency, and troubleshooting procedures. Commissioning and Start-Up We can identify, track, and control the thousands of activities that must occur for the successful commissioning and start-up of a process plant. There is no shortcut to a successful start-up. Testing and Tracking Systems We can help manage and track the performance of employees to improve the overall performance of the mine and plant industrial training programs. Our testing and tracking systems provide invaluable assistance in safety and operational compliance.  Introductory and Safety Training Off-the-shelf introductory and safety training packages are an excellent source for mine and plant industrial training courses. They provide fundamental knowledge and basic training concepts. Now offering online courses! E-Learning, Animations, and Simulations Our interactive e-learning keeps trainees focused and engaged. Our experienced in-house multimedia team develops state-of-the-art graphics, virtual and mixed reality training, stunning 3D animations, and technically engineered simulations of real-world scenarios. Other Services We also provide many services relevant to planning, analyzing, and evaluating process plants, including: ·         Operations readiness plan. ·         Planning studies. ·         Quality management. ·         Systems implementation. ·         Statistical process control. ·         Reliability-based asset management. ·         Productive capacity studies. ·         Surveys and needs analyses. ·         Economic life analysis. ·         Process control strategies and methods. ·         Debottlenecking and process optimization. ·         Spare parts inventory and analysis. ·         Feasibility studies. ·         Consulting assistance. Consulting * Gap Analysis * Content Development * LMS * On-Site * Train-the-Trainer * E-Learning * Process Plant Optimization * Training * Safety * Mine Training * Plant Operator Training * Maintenance * Mobile Equipment * Competencies * Commissioning  

Three dimensional animations integrated into a process plant computer-based training (CBT) program can greatly enhance trainee understanding of process equipment. This introductory maintenance manual and animation provides a narrative description of a jaw crusher’s location in the process, its function, components, and maintenance requirements. The animation introduces maintenance personnel to the jaw crusher in a dynamic visual context. The narrated animation replaced the standard text and graphics in the description section of the equipment maintenance (CBT) module. The descriptive text was adapted to a narrative form. Multimedia specialists used engineering drawings and photographs to create models of the equipment and animate the modeled images to illustrate the key concepts and components in concert with the narration.

During the final stages of metallurgical plant construction there is tremendous pressure to commence production. More often than not, there will have been budget overruns and schedule delays. Corporate management and investors are naturally anxious to generate cash flow. This pressure may evolve into a fast-track culture regarding the commissioning and start-up.  www.perfnet.com 

During the final stages of metallurgical plant construction there is tremendous pressure to commence production. More often than not, there will have been budget overruns and schedule delays. Corporate management and investors are naturally anxious to generate cash flow. This pressure may evolve into a fast-track culture regarding the commissioning and start-up. www.perfnet.com 

Mapping is one of the least understood applications for drones. Maps are very useful for many industries, but if your customers require accurate measurements, additional controls are needed beyond simple photo processing. As drone-based photogrammetry becomes widely accepted, it is important to note best practices that help ensure quality, trusted insights for your clients. In Andrew Maximow's latest article, he covers what is needed in a drone mapping system to produce and collect accurate, quality data. Check it out here.

Developing a profitable mining venture is no small matter. It requires enormous initial investments in research, construction, and equipment. But a mineral processing plant does not run itself. Even with the best equipment and good ore quality, optimal results are dependent upon keeping the process running smoothly, avoiding process upsets, maintaining process variables in the desired range, and minimizing breakdowns and downtime. A highly trained workforce is an essential element in a successful, and profitable, start-up. The knowledge and abilities of plant operators and maintenance personnel can make or break an operation. Trained operators know what to look for during preoperational and routine inspections, allowing maintenance tasks to be planned and unexpected costly breakdowns avoided. Trained operators know what variables exist at different stages in the process and how to make appropriate adjustments in real time. Trained maintenance personnel are well acquainted with the plant equipment, and maintenance planners can schedule work and maintain a spare parts inventory to minimize downtime. Additionally, new operations that train their workforce just prior to plant commissioning can utilize their operators in the commissioning process. Having been trained and gained field experience through plant commissioning, operators are ready to hit the ground running once feed is introduced. A faster ramp-up means more earnings, more quickly. The cost of developing a proper training program is a small percentage of the overall engineering, procurement, and construction budget but it constitutes a large percentage of the gains realized from a successful start-up and ramp-up to full production. Performance Associates International (PAI) has designed and presented custom training programs for operators and maintenance personnel in metallurgical plants around the world for over 35 years. We are proud to have been part of the successful start-ups at Lundin Mining’s Eagle Mine, Vale’s Voisey’s Bay project, and Torex Gold’s El Limon-Guajes project. Click Download to view the actual vs. projected start-up results from these three metallurgical plants that made use of PAI’s custom-built training programs and on-site training.

Now more than ever, we’re aware of our personal data and how much we’re willingly handing out. Whether it’s through data uploads, social media, or allowing applications to have access to your personal info, it’s important to think twice about what you’re doing with your data. In our industry, we often receive questions related to data security concerns with drones, specifically about drones manufactured outside of the US. With this in mind, it’s valuable to equip you with an overview of the data security concerns being widely reported on and discussed in the media. Read our detailed article by Chief Drone Officer, Andrew Maximow to learn more.

In the past, we’ve discussed techniques and best practices necessary for precision mapping projects requiring a high degree of absolute accuracy. Not all clients require that level of accuracy, so different tools and techniques are used to create the deliverables. A one-size-fits-all solution in our industry isn’t practical, so we research and work with our clients to determine the best tool and software available for precise and efficient data collection and processing. In this article, Andrew Maximow compares the traditional way of processing photos along with two faster and more efficient methods that save time, processing steps, and resources. Learn more on the blog!

With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model. Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:  Process objective of each process system, comprising a group of unit operations.  Process objective of each unit operation.  Process chemistry and the variables affecting it.  Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.  Plant control loops, interlocks, and alarms.  Safety issues related to the process and control schemes.  Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks. Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training.

Drones have made it faster, easier, and safer to collect data. New drone tech has allowed us to develop better deliverables and custom solutions for our clients. But it hasn’t always been a smooth transition to new technology. We’ve learned a lot of lessons along the way, and we continue to learn them as our business grows. Learn more about the insights we've gained in our latest blog by Lauren Elmore!

With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model.  Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:Process objective of each process system, comprising a group of unit operations.Process objective of each unit operation.Process chemistry and the variables affecting it.Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.Plant control loops, interlocks, and alarms.Safety issues related to the process and control schemes.Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks.Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training. 

We were recently asked to inspect a large indoor construction site with a roof height of approx 100 feet. The project will eventually be one of the largest indoor mall and family entertainment complexes in the world. The site has experienced a rocky journey with construction that started nearly 20 years ago. The roof height poses a challenge for new owners and contractors. The only solution in knowing whether proper work has been done over the years? Indoor drone inspection. In this article, Andrew Maximow discusses this project and three significant challenges to deploying drones indoors. Learn more on the blog!

We know that geospatial data collection is increasingly accessible. But data is more than just a number. Real solutions come from understanding and analyzing the data that is collected. We work with our clients to develop meaningful deliverables for underground mining applications that save our clients money and improve their operations. Transforming data into actionable insights is what the Firmatek team delivers. Learn more about the data collection and analysis process in our case study by Seaver Hall, Project Engineer.

The geology report, feasibility study, and mine plan look great. Why do so many mining project start-ups fail to perform? Most mining companies put a great deal of emphasis on the nature of the reserve, the mine plan, the extraction process to be used, and the process plant design—obviously all very important. Even when large, highly regarded engineering, procurement, and construction firms develop the project, operating results are very often disappointing. In this paper, we explore the role of Operations Readiness on the financial impact of mining project start-ups. A relatively small investment in operations readiness produces a huge financial return. Many investment firms, as well as mining company senior executives, fail to consider this important factor in operating success.

Drone adoption is thriving in several industries and the aggregates and mining industry that Firmatek serves is no exception. Although drone tech is relatively new, drones are revolutionizing the way we work. However, with all of the operational benefits that drones bring to the table, there are a few concerns that contribute to lack of adoption. We tackle three common concerns in our latest article by Henzé (hen-zay) Gustave. Check it out here!

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom training modules and on-site training have improved start-up success and operations for clients on nearly every continent. We invite you to experience one of our e-learning training modules. Here you will see a video demonstration of a sample principle of operation from an e-learning module. A principle of operation describes in detail how a piece of equipment or a process works. In this sample, you will learn about Jameson Cell flotation technology and how its design allows for more efficient mineral separation in a much smaller tank than traditional column and mechanical flotation cells. We describe in detail the key components of the Jameson Cell and the operating principles. At the end of the module, a test will help assess what you learned. In a full training program, test results can be recorded and tracked in an LMS. A principle of operation like this would be only one of many included with a full plant operations training program. Note: This is a sample and does not contain the Jameson Cell training module in its entirety. If you would like to try out this e-learning module, please contact Kenneth Slack at [email protected] or +1-520-544-2220.

How can the overall performance of your plant be determined? Most plants calculate availability, or the percent of the time the plant or a particular circuit is operating, as well as overall production and recovery. But, is this information enough? Does it provide sufficient fine-grained information on where improvements can be made? This paper suggests five quantitative factors applied to a plant or to individual parts of a plant that identify the productivity of the plant—in other words, its productivity profile.

In this interactive PDF, we talk about common training myths and our responses.

How can the overall performance of your plant be determined? Most plants calculate availability, or the percent of the time the plant or a particular circuit is operating, as well as overall production and recovery. But, is this information enough? Does it provide sufficient fine-grained information on where improvements can be made? This paper suggests five quantitative factors applied to a plant or to individual parts of a plant that identify the productivity of the plant—in other words, its productivity profile.

Ensure that your plant has a good inventory of spare parts on hand by learning how to collect the data necessary to build your own spare parts inventory model.

Haver & Boecker Niagara offers a full diagnostics portfolio by combining the Pulse Impact Test, Pulse Vibration Analysis, and Pulse Condition Monitoring to give aggregates and mining producers a more holistic view of their mineral processing equipment.

Belt conveyor systems can solve complex transport problems involving bulk materials of all kinds. When choosing the components of a system, you have to consider factors like wear resistance and maximum permissible slopes. How is the BEUMER Group able to develop the perfect solution for your application and deliver it to you? You’ll get answers from Christoph Dorra, Regional Sales Manager for South America, Conveying and Loading Systems, and Martin Rewer, Team Leader for Overland Conveyors.