Tata Steel’s Noamundi Iron Mine in Jharkhand, India recently achieved significant load and haul efficiencies from a continuous improvement project supported by Immersive Technologies and Vareli Tecnac (VTPL).  The project objectives stemmed from analysis of Wenco Fleet Management System (FMS) data which identified operational trends linked to specific operator behaviours.  The analysis also showed variability in how operators were performing tasks, especially around machine care, productivity and fuel efficiency.

To reduce the performance variability, a targeted workforce upskilling program was conducted at Tata’s training center located at Joda East Iron Mine.  The simulator training was conducted by an Immersive Technologies embedded trainer with support from VTPL, and focused on a Komatsu HD785-7 truck and Hitachi EX1200-5D face shovel. To measure the effectiveness of the solution, mining data was measured before and after training.

Quantified operational improvement for the Hitachi EX1200-5D for in-pit (real results) translated to a 40% better mean loading time with an estimated 5 litres of High-Speed Diesel (HSD) saved per loading cycle. The simulator results for the machine saw the average loading time per truck value improve by 2%; the instantaneous dig rate average improved by 6%; the average fill factor improved by 7% and overall operator competency improved by 57%. For the Komatsu HD785-7, the in-pit (real results) saw a 4% fuel consumption improvement while for the simulator, operator fuel efficiency behaviours improved by 79%.