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 behaviors. 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 Improvements:
Hitachi EX1200-5D
In-Pit (Real Results)
- 40% improvement in mean loading time with an estimated 5 liters of High-Speed Diesel (HSD) saved per loading cycle
Simulator Results
- Average Loading Time per Truck value improved by 2%
- Instantaneous Dig Rate average improved by 6%
- Average Fill Factor improved by 7%
- Overall operator competency improved by 57%
Komatsu HD785-7
- In-Pit (Real Results): 4% fuel consumption improvement.
- Simulator Results: Operator Fuel Efficiency behaviors improved by 79%.