Cipta Kridatama, one of Indonesia’s leading mining contractors, improved haul truck fuel efficiency by 6.9% using simulation based training earning them Immersive Technologies’ Global Business Improvement Award for 2013. The award recognises the achievements of mine sites focused on improving operational safety, efficiency and productivity through strategic and focused training initiatives. Cipta Kridatama was chosen as the recipient from more than 250 global mining operations in 35 countries. Cipta Kridatama joins other award winners such as Cliffs Natural Resources, Syncrude, Kinross and Peabody.
Presenting at a recent Immersive Technologies Users Group Forum, 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 litres/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 litres/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.
A comparison of fuel records between pre-simulation and post-simulation based training showed an improvement of 6.3% in one month. On site fuel usage went down each month thereafter with the last reported usage showing a 6.9% overall reduction.
The site is now operating 5.8% under the budgeted litres/hour fuel consumption.
“Production time was not affected with these improvements and we believe, with a conservative estimate, we can save $500,000 per year through this training initiative,” Perdana said.
The haul trucks have a standard refuelling schedule and with tanks being fuller a secondary improvement was also calculated with refuelling taking less time, thereby increasing production time.
The fuel efficiency initiative showcased unique insights into how changes to operator behaviour affect cost savings through reduced fuel consumption.
The technology driving these fuel savings has now been embedded into SimControl, the software at the heart of Immersive Technologies’ leading range of Advanced Equipment Simulators. This technology is designed to enhance the way mining equipment operators learn to work in a productive manner while eliminating behaviors linked to negative outcomes such as excess fuel consumption. All Immersive Technologies supported customers now have access to this industry leading technology.
