Gold Mine, Ghana

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What did we do?

DCA delivered a full 18-month drilling optimization program including:

• Training and support programs for.
  - drill operators
  - offsiders
  - supervisors & leading hands
  - mechanics
  With an unofficial drill bits and rock tools management program
• Resourcers for training purposes:
  - Evaluation matrix per program to establish base line and pattern recognition
  - Workbook detailing and recording full program: record of theory training and assessment, practical training delivery, consolidation phase and assessment
  - Sandvik DPi simulator training
• Reduce rock tools CPM
• Increase utilization rates of drills
• Increase availability rate of drills
• Achieve better correlation between linear drilled meters and blasted volume
• Re-drilling rates
• Productivity rates per engine hour of drills
• Improve shift reporting and data captured
• Improve cross department communication
• Staff ownership and responsibilities – staff job descriptions for accountability

During the program, DCA held altogether 160 courses to 130 participants.

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Drilling optimization results & feedback

The program was very successful. One of the KPI's, +15% improvement on drilled meters per engine hour, was clearly surpassed. The key here, though, is efficiency as the initial target KPI of reducing rock tools cost per meter was -15% but the reduction was more than double, -54%.
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Despite aging equipment, the availability percentage has improved to over 85% from a sub 70% level. Total fleet productivity and efficiency increased to the level where total fleet size is possible to reduce by about 25%

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Mechanics commented on how many aspects of the machine and its functionality really opened up to them. Adopting the learnings to everyday repair and maintenance work is showing results. Drillers found that they understand the control system functionality and configuration better, which opens new techniques for drilling more efficiently.

In all cases, staff thought they already knew everything but learned quickly that there is so much they did not know.

The outcomes were achieved due to multiple factors: 

• increased fleet productivity and efficiency to the level where totalfleet size is possible to reduce by about 25 %
• Improved hole accuracy and minimized deviation due to better understanding of collaring and drilling pressures
• Understanding the control system functionalities and how to set parameters to allow the system to operate as engineered
• Minimizing “stuck in hole” situations due to better understanding and control of automated systems
• Significant reduction in redrill percentage because of improved collaring techniques and drilling support functions by personnel
• Over drilling minimized by implementing backup procedures to depth counter failures
• Rock tools maintenance procedures enforced to achieve maximum bit life, sustained pen rates and minimized stress on rock drill component