COMPANY INTRODUCTION Ambuja Cements was set up in 1986. In the last decade the company has grown tenfold. The total cement capacity of the company is 18.5 million tonnes. Its plants are some of the most efficient in the world. With environment protection measures that are on par with the finest in the developed world.The Groups principal activ ity is to manufacture and market cement and clinker for both domestic and export markets. COMPANY BUSINESSThe companys most distinctiv e attribute, however, is its approach to thebusiness. Ambuja follows a unique homegrown philosophy of giv ing peoplethe authority to set their own targets, and the freedom to achieve theirgoals. This simple vision has created an environment where there are nolimits to excellence, no limits to efficiency. And has proved to be apowerful engine of growth for the company.
KASHLOG MINES➢The Kashlog limestone mine of Ambuja Cement is located near village Kashlog in Arki Tehsil of Solan District in Himachal Pradesh, its mining lease area is about 488 hectares.➢This mine was awarded SitaRam Rungta Memorial award for social awareness for the year 1998-1999 by Federation of Indian Mineral Industries (FIMI).➢The total requirement of both the cement Plants Suli and Rauri is met from this mine.➢Crushed limestone from mine to plant is transported by a 3.2 Km long closed overland belt conveyor system in an Eco-friendly manner.➢The exploitation of limestone is being carried out by highly mechanized open- cast mining system.➢The 10m height benches are planned to have a slope of 70° with an ultimate pit slope of 45°.➢Drilling is carried out by deploying hydraulic drills for primary blasting purpose. Around 90% of the production requirement is met by drilling and blasting.
Crushed limestone from mine to plant is transported by a 3.2 Km long closed overland belt conveyor system in an Eco-friendly manner.
OBJECTIVES• To understand the operational activities of the mining process.• To calculate the cycle time of the various equipments of the mining process like dumpers, crushers etc.• To study about the safety precautions in the mining process.• To give a report about the assessment of the mining process to the management.• To report about the violations of the safety precautions and misconduct done which may or may not result to production loss.• To give a presentation at end of the project to the management and submit a good project hard-copy to the company.
RESEARCH APPROACHThere are different research methodology has been taken place tocomplete the project: First studying about mining activities from the internet. Second referring the books related to operations & supply management, to implement the various techniques and models for the project design and management. Third consulting with the various employees of different designations to extract the data for the project and understanding the environment of work. Fourth to go to the field of extraction of limestone and manually gather the recent cycle-time of various equipments. Fifth going to the different sections to gather the data at different points. Sixth I have also done some calculations at certain points.
FINDINGS/ PROBLEMS➢It has been observed that crusher is of under capacity. Crusher should be of 1200 TPH tofeed both the plants from single mine. Average crusher TPH in a shift was found to be 944TPH on an average.➢It has been observed that the hopper on a particular shift was only 79% full at maximumtime interval instead of 100% or 90% which means the interval of dumpers to dump the rawlime-stones into the hopper is not adequate. Some of the time intervals between the dumpers are as follows: From first dumper to 2nd : 5 min From 2nd to 3rd : 2 min From 3rd to 4th : 2:30 min From 4th to 5th : 3:45 min From 5th to 6th : 8:26 min From 6th to 7th : 4 min From 7th to 8th : 9:30 min From 8th to 9th : 1 min From 9th to 10th : 13 minTaking the average time between the dumpers, the time interval between in approx 5:30 min which is not enough to fill the hopper and utilize its optimum capacity.
FINDINGS/ PROBLEMSHere some sample of the dumpers cycle time is taken in a particular shift anddepended upon this some findings have been calculated: SL Transport Spotting Loading Transport Spotting Unloading Total no. time to time in time time to time to time to Cycle site site crusher crusher crusher time 1 6:20 min 3 min 1:35 min 8 min 4:30 min 00:21 sec 23:06 min 2 5 min 3:54 min 2:00 min 4:12 min 26:91 00:23 sec 15:16 sec min 3 3:51 min 2:58 min 2:15 min 4:00 min 1: 46 min 0:30 sec 14 min 4 3:37 min 15 min 2:56 min 4:00 min 00:16 00:34 sec 25:43 sec min By looking at the table we can see that the cycle time variation is large due to variation in lead distance. The highest cycle time here is nearly 26 min. After seeing the figures it could be easily pointed out that the variation is likely due to the idling time at crusher and loading point of excavator.
FINDINGS/ PROBLEMS➢The problem of excessive idling time in the extraction area is more likely due to the excess of dumpers in compare with the PC Excavators. Due to this after completing the cycle up to unloading and return for re-load, more than 2 dumpers have to wait in a line before the previous dumpers is loaded and ready to go. This is mainly due to low crusher capacity.➢Some times in place of 3 dumpers which are needed for the purpose, 4 dumpers are used and so due to the spotting time excessive amount of fuel is consumed. As we know that a dumper nearly consumes 25-28 liters per hour and in idle time In engine start position it consumes 5% of the total fuel per hour. So, nearly 1.4 liters it is consuming unnecessarily per hour. And considering it in a financial year it is a big loss.➢Sometimes it has been observed that the dumpers capacity is 50 tons but some dumpers carry 38 tons, 40 tons, some times 55 tons-58 tons which is over weight, so sometimes dumpers adequate capacity utilization lacks for which some production problem may also arise.
In place of one dumper 2 dumpers are waiting for loading.This is a picture has been taken at the lime stone extractionarea.
SUGGESSIONS●The cycle time of the equipments should be minimized like the dumper by employing certain techniques like minimizing the idle time of thedumpers at the extraction area by limiting the use of more dumpers inplace of few needed.●Or by increasing the numbers of PC excavators in the ratio of the dumpers like now there are 3 excavators, there should be 1 more.●When the dumpers are in idle position the engine should be switch off which may result in saving the fuel.●The maximum attention should be given to utilize the optimum capacity of the hopper at the crusher, so that production can be increased.●Optimum utilisation of the machines should be done to increase the output.
SAFETY PRECUATIONS UNDERTAKEN IN MINING AREAOnly the authorized employees are permitted to handle the explosives.There are demarcations around the blast location like barricades, flag signs etc.The blast holes are being loaded under the control and supervision of the designated competent person.The controlled blasting technique is being adopted.Cellular phones are not allowed in the blasting zone.The explosive vans speed should not exceed 25km/hr.Warning signals are given within a radius of 500 meters from the place of firing.After the blasting a siren is blown as signal if it is all clear and safe.As the blasting is very dangerous for the eye at some distance also, safety glasses should be provided and used at the blasting site.
SAFETY PRECUATIONS➢In the mines the Helmet & safety boots should be worn every time specially in the field.➢The use of safety glasses should be encouraged➢In the night shift there should be adequate light facility.➢The vehicles speed at the mines area should not exceed 30 km/hr under any conditions.➢The distance between the dumpers should be more then 10 meters..