1. Time Studies on 45 Level Development Ends (15 Sep-10 Oct 2011)
KDC EAST 4 Shaft (IKAMVA)
45/66, 45/64,45/61,North & 41/70 (Morning and Afternoon Shift)

2. 45 Level Background & Scope
General information and sequence of studied work places
(2.) 45/64 (South) (HPE 10)
 Shift is often delayed due to waiting for hoppers before loading span one (142 min)
 Hydraulic loader (27) is used, also faces breakdowns. Scoop going down slowly
(84min)
 Temperature 35°C (22 & 26 /09/2011) but crew completed cleaning
 Crew normally goes to the station tips before loading span 1 (137min)
 9 hoppers per span, 7min loading & 6min Shunting (15-17 hoppers loaded/ shift)
 Crew ‘s loco taken by tramming and cleaning was not completed (26/09) (23:56)
(1.) 45/61 (South) (HPE 5)
 Travelling time to work place (48min) & Crew is able to plan for hoppers in time to
start cleaning process
 Hydraulic loader (29/28) is used, breakdown delays(50min)
 Able to use two locos during a shift, extra hoppers were used when lost blasts
occurred on other workplaces (23/09) (45/66 had a lost blast)
 Temperature was cooler (27-30°C) during observed dates
 9 hoppers per span, 4min loading & 6 min shunting (15-17 hoppers loaded/ shift)
 Loco breakdowns whiles travelling to the tip station (3hrs:17min) (16/09)
(3.) 45/66 (South) (HPE 3)
 Shift is often delayed due to waiting for hoppers before loading span one (107min)
 Hydraulic loader (L26) is used, also faces breakdowns. Scoop going down slowly
 9 hoppers per span, 8min loading & 5min shunting (15-17 hoppers loaded/shift)
 Loader often derailed due to improper installation of jump sets and causes delays
 Drilling is affected by mostly short breakdowns that occurs and spare parts are
being collected far away ( next to waiting place)
 Crew reports that shortage of hoppers is the reason behind the delay of searching
and arranging hoppers before span one is loaded.
(4.) 45/36 North & 41/80 HWD
Two locos are used and shifts are made shorter
45 North side temperature (35°C) (27/09/2011) where the Sandvik drill rig is operating
41 level uses the tramming loco with a full span 1 and then use the development loco
for span two and finish their cleaning but not properly as ore was left on foot wall at the
face after loading 18 hoppers.(10/10/2011)
Delays were observed to be at the beginning of the shift due to tipping of hoppers from
the afternoon waste tramming shift on the level from 40 level (35min) before travelling to
waiting place.

3. 45/61(South)

4. Afternoon Shift
 Cleaning cycle
Time before starting to load span 1
-Shaft schedule affects the time
spent at sub shaft (56min-32min)
-16,26/09 crew used loco to travel to
w/place (mostly delayed by looking
for hoppers)
-barring is affected by loco arranging
hoppers before loading span 1
Loading span 1 and 2
-15,16/09 loader 29 experienced
breakdowns (57min) but (Loading
time 4min & shunting time 4min)
-22,26/09 2 locos were used
-15,16/09 loco traveled to tip station
and faced delays when coming
back ( tramming congestion )
-19 hoppers loaded (27/09)
Time crew knocks off
-Cage schedule affects time to
surface when knocking off
-Time in 5:57pm – Time back on
surface early 03:15am, late
05:13am
10 9 8 11 10
56
37 40 32 41
12
7 12 24 14
60
57 40 36 48
13
0 5 5
24 43
31 36 34
106 113
71
83 93
224 213
93
0
133
41 27
11 129
52
8
21
26
18
10
10
16
32
39
11
25
34
35
90 36
49
74 94
41
72
70
0
100
200
300
400
500
600
700
800
15/09/2011 16/09/2011 22/09/2011 27/09/2011 Average
Time(min)
Observed dates
45/61 FWD
21.Time from station to surface
20.Time crew knocks off at workplace
and travel to station
19.Time end is barred solid and
cleaned.
18.Time rails are extended
17.Time Jump sets are extended
12.Time loco goes and come back from
tip station- span 2
11.Time started to load with loader span
2
10.Time loco goes and come back from
tip station- span 1
9.Time started to load with loader span
1
8.Time barring and face preparation
begins
7.Time travel to workplace
6.Time spent at waiting place (Meeting)
5.Travel time to waiting place
4.Time into cage- sub shaft
3.Time spent at sub shaft
2.Time into cage- main shaft
502min Shift duration
2 locos used
1 loco used

5. 5
Morning Shift
 Drilling and Blasting Crew Time before drilling starts
-Travelling to waiting place 50min walk,
-21/09- 35min delay caused by arranging locos
and man carriages before travelling to waiting
place
-22/09- (During marking) waiting for loco to take
machine to face/miner still marking the other
work places and 45/61 being the last
Time drilling starts
-Drilling support holes 68min (23/09= 152min)
-Time to drill one hole 7:38min/support hole v/s
4min /face hole (23/09)
-Caused by hydro power supply when all the
machines are working.
-Installing support and charging up took place
at almost the same time.
Time crew knocks off
- 7 people in a crew were charging the face
21,23/09
-Time from station to surface (60 min)
-Time in 05:50am –time out 17:00 pm
8 16 13 1212 0 0 4
10 8 9 9
85
62 51
66
5
0 15
7
4
34
10
16
6 31
10
16
10
5
18
11
31
60
18
36
9
36
1525 19
15
11 4
64 71
152
96
145
176
134
152
11
461
57
53
57
69
74 30
58
5
5 337
31 40 36
27
60 45 44
0
100
200
300
400
500
600
700
800
21/09/2011 22/09/2011 23/09/2011 Average
Time(min)
Observed Date
45/61 FWD
22 Time on surface
21 Time crew travel back to the
station
20 Time crew knocks off at workplace
19 Time charging up the face begins
18 Time crew started to install support
17 Time the drill rig was removed
from the face
16 Time the rig started drilling face
holes
15 Time the drill rig started drilling
support holes
14 Time drilling pilot holes begins
13 Time to prepare the drill rig
(machine set up)
12 Time the drill rig arrives at face
11 Time spent for marking the face
begins
10 Time testing for ventilation and gas
begins
9 Time treating of sockets begins
8 Time washing the face begins
7 Time travel to workplace
6 Time spent at waiting place
(Meeting)
5 Time travel to waiting place
4 Time into cage- sub shaft
3 Time spent at sub shaft
2 Time into cage- main shaft
502min (Shift duration)

6. 45/64 (South)

7. Afternoon Shift
7
Cleaning Crew
8 8 11 9
23 40 32 32
16
12 24 17
48
61 36 48
16
44 307
7
6
7
142
84
93 106
197
180 101
159
62
62
5
5
7
6
130
35
37
67
111
107 80
99
0
100
200
300
400
500
600
700
800
21/09/2011 22/09/2011 27/09/2011 Average
Time(min)
Observed Dates
45/64
21.Time from station to surface
20.Time crew knocks off at
workplace and travel to station
19.Time end is barred solid and
cleaned.
18.Time rails are extended
17.Time Jump sets are extended
12.Time loco goes and come back
from tip station- span 2
11.Time started to load with
loader span 2
10.Time loco goes and come back
from tip station- span 1
9.Time started to load with loader
span 1
8.Time barring and face
preparation begins
7.Time travel to workplace
6.Time spent at waiting place
(Meeting)
5.Travel time to waiting place
4.Time into cage- sub shaft
3.Time spent at sub shaft
2.Time into cage- main shaft
502min Shift duration
Time before loading
span 1
• Time barring face and preparation
• -Loco goes to the tip station first (21/09) (
127min)
• -Searching for hoppers (22 & 27/09)
• Temperature (35°C) (22/09)
Time Loading span 1
and 2
• 21/09) 13 hoppers were loaded in span 1
• Loader derailed (24min)
• -(22/09) 12 hoppers were loaded in span
1
• Hopper derailed (15min)
• -(27/09) 8 hoppers were loaded & Loco
could not come back from station
tips.(tramming crew took the loco No.36)
• -Loading time 7min & Shunting time 6min
Time crew knocks off
• Crew goes with hoppers to the tip station after
loading one span
• -21/09 crew traveled 59 min to station and
waited ( 71min) before cage came to the level
• -cage at sub shaft also delayed 40min
Cleaning
not
completed

8. Morning Shift
8
Drilling and Blasting Crew
Time before
drilling starts
• Time travelling to waiting place
• Crew arrive late at waiting place due to arranging
hoppers at station & waiting for other crew members
(man carriages are used)
• Temperature 33°C (21/09) 31°C (22/09)
• Marking is also affected by the miner and work
places allocation
Drilling time and
charging up
• 12-16 support holes drilled at 5min /hole
• 52 face holes at 6min /hole (2.4m jumper)
• Clamps broke on machine and needed to be changed
(21/09) (72min)
• Crew could not get combo valve in time , water pipe
damaged needed repair (61min) (22/09)
• 8 people charge the face after drilling (21,22/09)
• Installing support takes place after drilling support
holes
• 13/10 crew were slow in charging up and 4 people
were charging the face.
Time crew
knocks off
• Time factor (Finishing drilling face holes late) affects
the way crew operates towards the end of the shift.
20 16 10 15
40 139 8
12
10
58
92
61
70
18
20 15
18
60 5 11 25
10
10
29 16
10
30 13
24 24 24 24
26 26 26
10 10 8
17 17
16
17
43 54
37
45
215 204
143
187
10 10
6
9
25 25
39
30
60
40
100
67
5
10
3
6
35
30
34
33
30 60
45
45
0
100
200
300
400
500
600
700
800
21/09/2011 22/09/2011 13/10/2011 Average
Time(min)
Dates Observed
45/64
22 Time on surface
21 Time crew travel back to the
station
20 Time crew knocks off at
workplace
19 Time charging up the face
begins
18 Time crew started to install
support
17 Time the drill rig was
removed from the face
16 Time the rig started drilling
face holes
15 Time the drill rig started
drilling support holes
14 Time drilling pilot holes
begins
13 Time to prepare the drill rig
(machine set up)
12 Time the drill rig arrives at
face
11 Time spent for marking the
face begins
10 Time testing for ventilation
and gas begins
9 Time treating of sockets begins
8 Time washing the face begins
7 Time travel to workplace
6 Time spent at waiting place
(Meeting)
5 Time travel to waiting place
4 Time into cage- sub shaft
3 Time spent at sub shaft
2 Time into cage- main shaft
502min (Shift duration)

9. 45/66 (South)

10. Afternoon shift
10
Cleaning cycle
Time before loading
span 1
starts
• Searching and arranging hoppers affects time to
load span one.
• Shortage of hoppers reported to be the common
cause event.
Loading span 1 and
2
• Loader is consistently derailed (35min) and a
problem of moving down slowly during loading
(8min). Shunting (6min)
• Derailing of empty hoppers around switches
(37min)
• 18 hoppers (21/09) 16 hoppers (27/09)
• Jump sets extended while loco went to the tip
station (21/09)
Knocking off
• Crew goes with 2nd span hoppers to the tip
station
• Crew travelled by loco to the station but delayed
by cage schedule (21/09)
8 11 10
10
32 2113
24
19
48
36
42
5
5
5
39
2245
19
32
108
121
115
168 84 126
71
88
80
35
3531 2
17
47 62
55
90
60
75
0
100
200
300
400
500
600
700
21/09/2011 27/09/2011 Average
Time(min)
Observed dates
45/66
21.Time from station to surface
20.Time crew knocks off at
workplace and travel to station
19.Time end is barred solid and
cleaned.
18.Time rails are extended
17.Time Jump sets are extended
12.Time loco goes and come
back from tip station- span 2
11.Time started to load with
loader span 2
10.Time loco goes and come
back from tip station- span 1
9.Time started to load with
loader span 1
8.Time barring and face
preparation begins
7.Time travel to workplace
6.Time spent at waiting place
(Meeting)
5.Travel time to waiting place
4.Time into cage- sub shaft
3.Time spent at sub shaft
2.Time into cage- main shaft
502min Shift duration

11. Morning Shift
11
Time before drilling
starts
• 21/09 crew arrived late at work place- no loco
driver
• Machine derailed as well before starting to drill
(48min)
• 3 people were at the face through out the shift
(2 operators & 1 team leader)
Time drilling and
charging up
• Drilling time support holes (LB 5:26min,RB
3:45min)
• Drilling time face holes (LB-6:33min, RB 4:28)
• 1 spare jumper available (21/09)
• Machine pins that holds rock drills broke and
technician replaced it late. Left boom
(2hrs:16min)
Time crew knocks
off
• Crew walk to station and does not travel by
loco at times
• Shaft schedule does not affect the shift length.
8 8 14 10
15 22 12
10 5
10 8
55 63
48
55
29
17
1515 25 15
48 18
64
13
26
10
5
5
23
21
77
146
74
220
174
195
196
78
0
26
48
41
30
7
5
5
6
63
52
65
60
42
65
40
49
0
100
200
300
400
500
600
700
800
21/09/2011 22/09/2011 23/09/2010 Average
Time(min)
Observed dates
45/66
22 Time on surface
21 Time crew travel back to the
station
20 Time crew knocks off at
workplace
19 Time charging up the face
begins
18 Time crew started to install
support
17 Time the drill rig was removed
from the face
16 Time the rig started drilling
face holes
15 Time the drill rig started
drilling support holes
14 Time drilling pilot holes begins
13 Time to prepare the drill rig
(machine set up)
12 Time the drill rig arrives at
face
11 Time spent for marking the
face begins
10 Time testing for ventilation
and gas begins
9 Time treating of sockets begins
8 Time washing the face begins
7 Time travel to workplace
6 Time spent at waiting place
(Meeting)
5 Time travel to waiting place
4 Time into cage- sub shaft
3 Time spent at sub shaft
2 Time into cage- main shaft
502min (Shift duration)
Drilling not
completed
Drilling and blasting crew

12. 45/36 (North)
Afternoon Shifts

13. Afternoon Shift
13
Cleaning Cycle
Time barring and face preparations begin
-Crew started late to load span 1 due to
tramming locos congestion at tip station
(23/09) Delay
-Jump sets installed whiles loco went to the
tip station
-Loading time 4:42 min, Shunting time
3:24min
-Span 1 =9 hoppers and span 2 =9
hoppers (23/09)
8 8 9
51
12
45
5
10
16
45
75
59
19
5
120
32
36
82
104
85
90
124
76
41
72
8
0
25
15
34
67
53
73
86
0
100
200
300
400
500
600
700
23/09/2011 27/09/2011 10/10/2011
45/36 North & 41 Level (AS)
21.Time from station to surface
20.Time crew knocks off at
workplace and travel to station
19.Time end is barred solid and
cleaned.
18.Time rails are extended
17.Time Jump sets are extended
12.Time loco goes and come back
from tip station- span 2
11.Time started to load with loader
span 2
10.Time loco goes and come back
from tip station- span 1
9.Time started to load with loader
span 1
8.Time barring and face
preparation begins
7.Time travel to workplace
6.Time spent at waiting place
(Meeting)
5.Travel time to waiting place
4.Time into cage- sub shaft
3.Time spent at sub shaft
2.Time into cage- main shaft
502min (Shift duration)
45/36 North
41/70 XC
41 Level
Crew uses two locos of which one is for
tramming and they start with the tramming
loco first and then the development loco is
used for the second span,

14. Analysis of Observed Findings
45 level (South)

15. Key Focus
Morning Shift Drilling Cycle
Time spent at sub shaft is less (12-22min) (Shaft schedule does
not affect shift)
When crew arrives at station much time is spent at the station
tips looking for and arranging man carriages before travelling to
waiting place (travelling time to waiting place 55-75min)
Work elements durations before drilling support holes starts
are increased by loco driver not being available, machine
parts and technician not available and derailing of rig whiles
approaching the face. (Hence 1 technician, 3 work places)
Drilling and charging affected by having breakdowns on rock
drills and delays, shortage of number of people in the work
place, machine breakdown and availability of repair parts.
Hydro power system in the morning reported low pressures
slowing down drilling and then increase up later (45/61).
Afternoon Shift Cleaning Cycle
Time spent at sub shaft is more (21-56min) (Shaft schedule
affects shift length)
When crew arrives at station less time is spent at the station tips
before travelling to waiting place (42-48min)
Work element’s durations before loading span 1 starts are
increased by availability of locos and hoppers, derailing of
loaders and hoppers and loader breakdowns caused by
crew’s loader driver not taking loader to fitter workshop after
usage on the previous shift.
Loading affected by loader being derailed, Hoppers derailed
on switches, Loader breakdowns (turning on one side,
shovel moving down slowly) Locos face delays when
travelling to the tip station.
15
Contrast Between Drilling and Cleaning Cycles
76
114
13
6
124
48
0 50 100 150 200 250
Loco 28 (45/61) (16/09/2011)
Loco KB2 (45/66) (21/09/2011)
Loco Tracking
Time travel to tip station
Time spent at tip station
Time travel back to workplace

16. Areas of concern (Ikamva 45level)
Problems Identified and possible solutions analysis
16
Summary on issues affecting morning & afternoon shifts
Communication &
Management
Shaft schedule (crews going in and out underground)
-shaft schedule is to be followed such that crews don’t wait more that
15min at sub shaft
-1 hour in between sub shaft cages when knocking off after 1st cage on
level (afternoon shift)
Maintenance and management of equipments used for cleaning cycle
-crew’s responsibility to make sure loaders and locos are taken to
workshops for breakdowns.
-clearly distinguish between tramming equipments (hoppers) and
development and operation plan to be reviewed or re-plan
Hoppers availability
-Sharing hoppers in a space of 172min with the reef tramming crews on
the level :Shaft schedule (night shift time down – afternoon shift time)
-Maintenance on breakdown causes an increased mean time to repair
hoppers hence small in number (1 week standing)(45/61)
-Behavior of workers willing to be in possession of more hoppers and
hide them (45/64 & 66)
Mining related incidents
-Installation of jump sets, rails and ventilation systems on the work place
need attention as the common cause for delays during cleaning were
related to loader derailed, hopper derailed on switches etc.
-safety standards compromised (temperature), not blasting to full
potential (breakdowns),charging up process (45/64) and hydro power
supply division between the work places (45/61)
Morning shift and factors affecting drilling
-Delays caused by parts availability on machine and rock drills
(mean time to repair )
-supervision of crews & workmanship (miner) (45/66)
3
2
6
4
7
6
2 3
10
3
6
10
1 4
11 10 7
16
45 45
144
63
117
144
34 37
135
33
111
115
0
20
40
60
80
100
120
140
160
0
2
4
6
8
10
12
14
16
18
39 Level40 Level41 Level 42 Level43 Level45 Level
Numberofhoppers
NumberofLocos
4 Shaft locos and hoppers
Tramming Locos
Development Locos
Work places
9 hoppers/loco rate
Hoppers available
(Data supplied by Engineering Dept)

17. Conclusions
 Afternoon shift
 The study indicates that sharing of equipment affect the afternoon work cycle and needs to be addressed. Management will have to review the two options
available for further improving the cleaning cycle.
1) To operate in such a way that hoppers are not looked for and not a problem hence sharing with night shift reef tramming crew provided there is an efficient
way of managing the maintenance on breakdown situation (Communication & Planning).
2) Have enough equipments (hoppers & Locos )to support the work cycles, have planned (preventative) maintenance on them and follow up on how else best to
manage and operate effectively.
 The afternoon shift should be accommodated by the shaft schedule so as to prevent shift delays within the afternoon work cycle.
-Time for the next cage must be reviewed per level at least 30 min difference between two points if possible when the afternoon shift knocks off.
 Crews must see equipments that are not in good working conditions and need to be handed over to the fitter workshop for repair when knocking off as it delays
the next shift when loading span one (Supervision) (Lower management)
 Temperatures must be kept cool or below 31°C as this is according to safety standards, crews then work in abnormal working conditions and may lead to
unsafe work practices (Lower management).This compromises safety and is totally unacceptable.
 Crews must also make sure that all hoppers are tipped ( tip the second span and other full hoppers when knocking off) it delays the next cleaning cycle.
 Morning Shift
 Breakdowns and operational delays affect the face drilling time in total and would require more investigations to be made paying attention to rock drills, rig
machine breakdowns and delays allocated to operators.
 Machine parts , spare jumpers and other facilitating materials are to be kept near the work places where rigs are operating so as to eliminate delays caused by
breakdowns requiring repairs during drilling.
Further Investigations are still to be made for final conclusions and recommendations to be made.
17
Based on the observations