ReportPlusDemo

VICE Review Validated Baseline
with gap analysis
Mogalakwena Mine

+ 0
Improvement Opportunities Identified
0
Skills Improvements
0
Equipment Issues to Address

Key Findings Summary

Hover over the card to reveal a key message.

Key Challenge

Operating processes and expectations are only partially documented and variably understood and applied on site

Opportunity

Review and update the Traffic Management Plan developing companion procedures and

Group Standards

There is a shortfall in guidance from Anglo American in regards to equipment

Opportunity

Develop guidance on selection, introduction to site, maintenance regimes and engineering for technology integration

Mine Life Planning

The site has a long mine life and standards may not be adequately considering the potential opportunities

Opportunity

Sieze the opportunity to integrate digital technologies - identifying data streams that can help with efficient operation as well as collision avoidance

Monitor for Drift

Many of the key business inputs are not being adequately monitored - with supervision as the only means of gaining signal

Opportunity

As part of preparing functional requirements (as part of OEM engagement / equipment selection) include requirements for providing data streams, reports and alarms off vehicle

Follow Up

Develop Projects to Address OFI's

The key findings and themes from the VI Baseline review material should form the basis of projects (agreed actions) that address multiple Opportunities for Improvement.  Consider implementing one project for each of the themes around People Skills, Equipment Standards, Road Infrastructure, Traffic Planning and Systems improvement.

Table of Contents

Executive summary

Anglo American is committed to improving vehicle interaction controls across their operations. In South Africa Anglo-American Platinum, De Beers, and Kumba Iron Ore are represented on the AngloAmerican Collision Avoidance Systems (AA CAS) working group.

The AA CAS working group commissioned this Vehicle Interaction Control Effectiveness (VICE) review baseline to compare mine performance at the Mogalakwena Mine against; company expectations; industry good practice, and current and developing South African legislative requirements.

Output from this Mogalakwena VICE review baseline will be used to:

  • Address gaps in current site vehicle interaction controls at site
  • Identify opportunities to enhance existing approaches at site
  • Provide further detail on information to support the re-introduction and operational integration of CAS technology intended to improve vehicle interaction controls at Mogalakwena
  • Assist the Anglo American to prepare a Group resource that supports the successful deployment and operational integration of technology solutions across the business

The VICE review baseline is not an audit. Instead, it is a process that captures, structures and updates information about the effectiveness of current site vehicle interaction controls at Mogalakwena initially ‘as documented’ and then after review by experienced and knowledgeable personnel the information is updated to ‘as done.’ When sorted this way improvement opportunities can be patterned and analysed at both granular and systems levels.

Its purpose is to assist an Mogalakwena mine and Anglo American to select and integrate technology that will enhance or replace current vehicle interaction controls. This includes capturing and analysing aggregated data streams for use in in managing mine design and operational controls. This review also:

  • Provides a process for preparing detailed information for potential technology providers through site User Requirements
  • Assists with future operational integration of new CAS technology
  • Builds organisational capability so that the Mogalakwena VICE Baseline can be maintained and updated through each project step

Adapting and applying the EMESRT Control Framework

Over the last half decade, Anglo American has been an active industry leader, contributor, and supporter of the development and implementation of vehicle interaction controls, notably through the International Council on Mines and Metals (ICMM) and the Earth Moving Equipment Safety Round Table EMESRT.
  • Anglo American is a foundation member of EMESRT which was formed in 2006 and the Control Framework (CFw) Approach described below, is informed by company experience.
  • Based on Design Philosophy 5 – Machine Operation & Control, and starting in 2013, EMESRT has facilitated a range of industry-level projects to improve the reliability of vehicle interaction controls in mining. The initial projects supported the development of improved controls for awareness, advisory and intervention technologies as illustrated in the 9 Layer model figure (levels 7-9).
  • After three years of project work by RTIO, EMESRT and others there was a realisation that if system level step changes are to be made to improve the reliability of vehicle interaction controls, then comprehensive reviews of design and operate controls (Levels 1 – 7) are also required.
This requirement for a review of multi-level controls that are dynamically linked saw the development of the EMESRT Control Framework (CFw) Approach described in the next section. Further information about the EMESRT Industry Project for Vehicle Interaction Control Improvement, including key outputs, is provided in Appendix D.

VICE Baseline Key Findings

Mogalakwena Operations are reported as good, well-led operations with satisfactory vehicle interaction controls, however:

  • Are you doing enough to stay good?
  • As leaders, are you concentrating on the right things?
  • Are you able to detect drift in performance and make corrections before serious incidents?
  • Can you get better, can site existing site vehicle interaction controls be improved i.e. made more consistent and reliable and aligned with Anglo American expectations?
  • Will you be ready to introduce new technology controls in the coming months?

Operators and all people working around mobile equipment are trained, competent, authorised, informed, alert and situationally aware.

This group of business inputs focuses on ensuring:

  • Operators in control of mobile equipment are trained, competent, authorised and situation aware.
  • People who routinely work around mobile equipment are trained, competent, authorised and situation aware.
  • People who are visitors to locations where mobile equipment operates are authorised, supervised and situation aware.
  • Mobile equipment operational requirements (task assignment) are effectively communicated by supervisors to the workforce.
  • Mobile equipment operations are monitored and adjusted to remain safe and productive e.g. credible failure modes that can compromise alertness and situational awareness are identified and managed.

Mobile Equipment is fit for use, key systems are functioning. 

This group of Business inputs focuses on ensuring: 

  • Fit-for-purpose mobile equipment is selected for use. 
  • Equipment is maintained to be operationally safe and productive. 
  • Support equipment e.g. radio communications, Wi-Fi networks are fit-for-purpose and reliable in service.  
  • Equipment failures during operations are notified and managed. 

2.3.1 – During the detailed control sheet review and validation, workshop attendees considered 22 Venetia Business Inputs in this category and identified opportunities for improvement for 17. A total of 43 opportunities for improvement were identified. 

2.3.2 – This high number of opportunities for improvement (43) for the Mobile Equipment category may be a symptom of the transition from 10 years of mine development into production. However, it may also point to a general opportunity to review site processes delivering mobile equipment and consider both their design and application.  

2.3.3 – The Improvement opportunities are detailed in Table 4 below. Further details are also available in Appendix A – VI Control Baseline.

2.3.4 – At the closing session of the Venetia validation workshop these themes to restore or improve the reliability of Mobile Equipment related Business Inputs were emphasised by the participants:  

  • All stakeholders should be engaged prior to the selection of equipment. 
  • Regular checking and maintenance of speed measurement systems is not being conducted at VUP due to lack of resources. 
  • There must be a document detailing the requirements for registering contractor/hire vehicles on SAP. How do we onboard contractor machines? 
  • The robustness of the engagement process is inadequate. Technology suppliers are not providing sufficient aftersales support (SLA). 
  • There are too many alarms in the Operator cabin, alarms are being normalised negating their deign intent. 
  • There are opportunities to consult further with OEM’s to agree maintenance tactics and visual inspections for mobile equipment 
  • Work order schedule compliance concerns due to limited resources were noted. 

2.3.5 – Future technology discussions relevant to mobile equipment included these points:   

  • The integration of CAS with ADAS should be part of our approach. 
  • Opportunities for other third party safety system integration to reduce in-cab clutter and limit audible alarms should be fully explored.  
  • Look at installing a hands-free radio into the cab. 
  • Deploy sensor technology that assists with preventing collisions with obstacles and the environment. 

Related BIBI ExpectationOFI ReferenceWorkshop Comments
BI-02D.01 Fit-for-purpose equipment selection and site use approval processes.Equipment selected for site use is fit-for-purpose and delivers safe and productive outcomes – meeting all site requirements for worker ergonomics, control integrity, matching to existing site technology, equipment performance and operating environment constraints.  A110 – BI-02D.01 – Update the FFP requirements for vehicles to include checks for the number of add-on systUpdate the FFP requirements for vehicles to include checks for the number of add-on systems installed. Too many add on systems installed leading to: -reduced visibility; -increased noise
A180 – BI-02D.01 – Confirm what learnings are coming back from tyre incidents at MOGConfirm what learnings are coming back from tyre incidents at MOG – addressing comment – Question – What learning is coming back from tyre incidents at Mogalakwena?
BI-02D.02 Standards that set minimum requirements for cabin integrity, restraints, access and escape, auto-shut downs and other relevant protective systemsEquipment selected for site use is fit for purpose and delivers safe and productive outcomes.A188 – BI-02D.02 – Source and implement consistent seat belt alarms and monitoringSource and implement consistent seat belt alarms and monitoring – addressing comments – possible engineering control to start up
A190 – BI-02D.02 – NCAP 5 rating to be reviewed and certification for rops/fops requiredNCAP 5 rating to be reviewed and certification for ROPS/FOPS required
A192 – BI-02D.02 – Confirm ISO3449 is called up in the equipment selection (for deflection limiting volume)Confirm ISO3449 is called up in the equipment selection (for deflection limiting volume)
BI-02D.04 Processes for confirming that new to site vehicles meet site specifications including vehicle lights, signage and markings (Intro to Site)All site vehicles in operating areas meet specifications for vehicle reversing & head lights, running lights, indicator and identification numbers. A142 – BI-02D.04 – Confirm references and specifics for FFP checks plus provide guidance on contactorsConfirm references and specifics for FFP checks plus provide guidance on contactors – addressing lack of material provided before team session and comments around how contractor’s proof of maintenance are sourced and maintained
BI-02D.10 Operator ergonomics are considered for controls and before introducing vehicle alarms and other aidsControl panels/devices, alarms and other aids introduced to alert the operator and / or improve situational awareness add value and support cognitive ease for Vehicle Operators.A165 – BI-02D.10 – Confirm the seat shaker trials progress ergonomicallyConfirm the seat shaker trials progress ergonomically addressing comment – Currently trialling vibration alerts in the cabin
BI-02D.21 Mobile Equipment is speed limitedWhere required mobile equipment speed is effectively governed and is designed to be tamper proofA116 – BI-02D.21 – Provide references for speed limiting of equipmentProvide references for speed limiting of equipment. Nil response received on request for comment. Not referenced in FFP vehicle specifications.
BI-02D.53 Operator display specifications are detailed for mobile equipmentOperator displays provide the information necessary for safe and productive outcomes. A173 – BI-02D.53 – Review if there is a documented standard for alarm screensReview if there is a documented standard for alarm screens – to eliminate distraction (e.g. learning from Sission incident)
A174 – BI-02D.53 – Confirm the learnings coming from visiting human factor/ergonomist are includedConfirm the learnings coming from visiting human factor/ergonomist are included in an update of the equipment display specifications
BI-02P.01 All safety and operational systems on mobile equipment are maintained.Safety and operational systems on mobile equipment are maintained to a schedule and when they breakdown. Mobile equipment with compromised safety and operational systems does not operate.A176 – BI-02P.01 – Confirm PMO3 jobs in SAP for all maintenance requirementsBI-02P.01 & BI-02P.02: Confirm PMO3 jobs in SAP for all maintenance requirements
A186 – BI-02P.01 – Confirm electromagnetic compatibility with site for all TMM technologyConfirm electromagnetic compatibility with site for all TMM technology – addressing comment – Electromagnetic compatibility, Electromagnetic interference and interoperability
A187 – BI-02P.01 – Develop and implement a No-Go defect response for CAS/PDS failuresBI-02P.01 – Develop and implement a No-Go defect response for CAS/PDS failures – addressing comment – CAS/PDS failures need to be NO-GO and monitoring improved, need to include a monitoring dashboard
BI-02P.02 Regular checking and maintenance for cabin integrity, restraints, access and escape, auto shutdowns and other relevant protective systems.The protective systems and safety related components of on-site approved mobile equipment remain functional.A171 – BI-02P.02 – Review frequency and quality of over-inspection of maintenance checksReview frequency and quality of over-inspection of maintenance checks addressing comment – Confirm documentation available around accountabilities and communication on site
A176 – BI-02P.01 – Confirm PMO3 jobs in SAP for all maintenance requirementsBI-02P.01 & BI-02P.02: Confirm PMO3 jobs in SAP for all maintenance requirements
A193 – BI-02P.02 – Air bags will only deploy at speed this means that they are not effective on siteCheck – air bags will only deploy at speeds > 60km/hr – this means that they are not effective on site (as all site speeds are below this)
BI-02P.06 Operator pre-start checks include work area, communication system, safety devices, brakes, steering, tyres and running gear.Checks are made prior to use and as required through a shift to confirm that work areas or mobile equipment that is compromised does not operate. A175 – BI-02P.06 – Develop a common standard for defect reporting across the groupDevelop a common standard for defect reporting across the group – addressing comment – Capture the training and updating of the pre-use check lists – to try and get a fail to safe system in place for the whole group (common defect management system)
A178 – BI-02P.06 – Confirm if the pre-start checks include where operators place items such as crib tinsConfirm if the pre-start checks include where operators place items such as crib tins and other heavy items in the cab
BI-02P.07 Prestart radio checksThe communications equipment required for the safe and productive operation of mobile equipment is confirmed as working. Mobile equipment that cannot communicate does not operate.A141 – BI-02P.07 – Provide reference and specific information related to radio pre-start checksProvide reference and specific information related to radio pre-start checks – addressing lack of material provided before team session and comment that there is a requirement that within 3 hours of shift start to check for pre-use
BI-02P.08 Regular checking and maintenance of key systems, brakes, steering and tyresMobile equipment functionality – with a focus on brakes (including propulsion elements on electric drive vehicles), steering and tyres on site approved mobile equipment are monitored and well maintained.  A162 – BI-02P.08 – Confirm the frequency, quality and monitoring of regular test for key systems Confirm if there are regular brake tests using go/no-go gauges, inclined brake tests and per wheel testing
A182 – BI-02P.08 – Confirm N2 requirements align with leading practiceConfirm N2 requirements align with leading practice – addressing comments – Confirm – (Sission in place and should be part of critical controls) Wheel diameters of > 25″ have a N2 fill and maintenance system in place
A183 – BI-02P.08 – Confirm or implement early warning for N2 lossConfirm or implement early warning for N2 loss – addressing comment – Are there any early warning / issues related to loss of N2 in the tyres?
BI-02P.20 Tyre hazard awareness for equipment operatorsEquipment operators are aware of tyre operational hazards and their controls. A114 – BI-02P.20 – Address short fall in training around tyre hazard awarenessAddress short fall in training around tyre hazard awareness. Comment of – Operators not aware – truck operators.
A115 – BI-02P.20 – Schedule and conduct PTOs to confirm tyre hazard awarenessSchedule and conduct PTOs to confirm tyre hazard awareness. Address comment – PTO after training on tyre hazard awareness on truck operators.
BI-02S.05 Protocols for the calibration of key measuring equipmentMeasuring and position monitoring equipment is calibrated.A102 – BI-02S.05 – Confirm existence of PMO for calibrationsBI-02S.05 Confirm existence of PMO for calibrations
BI-02S.06 New communications or technology equipment, specification, test and commissioning processThe operational deployment of improvements/new communications and technology equipment is well managed and meets all functional and performance requirements – whilst causing minimum possible disruption to existing operations A144 – BI-02S.06 – Review the management and integration of any technology pilot projectsReview the management and integration of any technology pilot projects – addressing validation workshop comment questioning how pilot projects are managed
BI-02S.30 Equipment systems data sendEquipment system data is captured and sent for monitoring and analysis e.g. tyre pressure and temperature, acceleration, braking, engine revs, speed, etc. A172 – BI-02S.30 – Allocate resources to review and report on TMM dataAllocate resources to review and report on TMM data – to address comments – Data available – not being used but manpower allocation not done

Related BIBI ExpectationOFI ReferenceWorkshop Comments
BI-01D.01 Trained personnel who are supported by an appropriate and up-to-date training management systemA process should be in place for delivering and maintaining competency-based training.  A150 – BI-01D.01 – Review training management system to identify and action improvementsReview training management system to identify and action improvements – addressing team comments that Training updated material delayed/not done and Trainers not always competent in subject
BI-01P.01 Trained, Competent and Authorised Mobile Equipment Operators All workers who operate mobile equipment at the mine are trained and assessed for competency.  This covers equipment operation, other worker/infrastructure protection and maintaining control in the prevailing road conditions. A130 – BI-01P.01 – Confirm references and specifics related to training requirements for vehicle operatorsConfirm references and specifics related to training requirements for vehicle operators – addressing comments around information provided in Inductions, Procedures and License; Guidance for spotters and VFL processes.
A177 – BI-01P.01 – Confirm training requirements for loading of BukkiesConfirm training requirements for loading of bukkies – addressing comment – Confirm what standards are in place for transporting on bukkies a well as trucks at MOG
A191 – BI-01P.01 – Confirm if training modules includes a requirement to not have limbs protrudingConfirm if training modules includes a requirement to not have limbs protruding from the cabin
BI-01P.02 Task expectations are well communicated and reinforced over the work shift.Task performance expectations are clearly communicated at task allocation and then reinforced over the shift.A101 – BI-01P.02 – Follow up on the level of adherence to communication of tasksFollow up on the level of adherence to communication of task instructions for TMM operators. Current specification is not being adhered to.
BI-01P.05 Site clearance requirements and processes for accurately estimating distances – information prepared for OperatorsSite clearance requirements are documented and communicated in a style that is appropriate for the audience.A130 – BI-01P.01 – Confirm references and specifics related to training requirements for vehicle operatorsConfirm references and specifics related to training requirements for vehicle operators – addressing comments around information provided in Inductions, Procedures and License; Guidance for spotters and VFL processes.
A131 – BI-01P.05 – Confirm radar support for spotting vehicles is included in training and assessmentsConfirm radar support for spotting vehicles is included in training and assessments – addressing comment on guided spotting not being in place
A132 – BI-01P.05 – Review and enhance signage requirements and conformance around distance guidanceReview and enhance signage requirements and conformance around distance guidance – addressing comment that signage on site requires improvements.
BI-01P.06 Give way/Right of Way requirements information prepared for mobile equipment operators and pedestriansSite give way/right of way requirements are documented and communicated in a style that is appropriate for the audience.A161 – BI-01P.06 – Confirm ILIFA Africa Traffic Management Study (Audit) is in place at MOGConfirm ILIFA Africa Traffic Management Study (Audit) is in place at MOG. Addressing comment on use of ILIFA Africa on site made during the validation session.
BI-01P.08 Alarm and Vehicle information panel expected response – information prepared for OperatorsDeployed monitoring technology including alarms, automatic haulage system and vehicle information panel, with expected responses, are documented by vehicle type and communicated in a style that is appropriate for the audience.A104 – BI-01P.08 – Review what is required from the system in terms of audible warnings for excess speedReview what is required from the system in terms of audible warnings for excess speed. To address – Speed limit not adhered due to behavioral, no audible alarm for CAS, multiple systems alarming that could confuse the operator same time continuously
BI-01P.10 Minimum requirements for parking in any situation – information prepared for operatorsSite requirements for parking in any situation are documented and communicated in a style that is appropriate for the audience.A157 – BI-01P.10 – Confirm specific parking requirements address emergency park-up situationsConfirm specific parking requirements address emergency park-up situations – addressing lack of information provided prior to validation workshop and team comments on unknown park-up for tyre fires and offloading for service: park close to (but it is not designated).
A166 – BI-01P.10 – Confirm training resources contain examples of good parking practicesDocument good practice for parking at multiple levels. From design, operations to communication with operators.
A168 – BI-04P.13 – Confirm with Mogalakwena operators that the training in parking fundamentally stableConfirm with Mogalakwena operators that the training in parking fundamentally stable are included in general practices
BI-01P.12 Sight lines and blind spots by vehicle type – information prepared for vehicle operatorsSight lines and blind spot information by vehicle type is documented and communicated in a style that is appropriate for the audience.A138 – BI-01P.12 – Provide references and specifics around sight line and blind spot trainingProvide references and specifics around sight line and blind spot training – addressing lack of information provided prior to the team session
A139 – BI-01P.12 – Review cameras deployed on equipment to aid sight linesReview cameras deployed on equipment to aid sight lines – addressing comment that cameras need improvement
A140 – BI-01P.12 – Reinforce PTO and monitoring process for vehicle movements on siteReinforce PTO and monitoring process for vehicle movements on site – addressing comments that PTOs are Ineffective, and Vehicle monitoring reports only when incident occurred
A163 – BI-01P.12 – Confirm if sight lines and moving blind spots are included in training and designConfirm if sight lines and moving blind spots are included in training and design resources. Sight lines (to cover issues such as moving blind spots), lowering of berm heights, and intersection angles – are they applied in the design and construction of all intersections?
BI-01P.21 PPE, high visibility clothing, lights and alerting devices required in operational areas – information prepared for all personnelSite standards for PPE, high visibility clothing, lights and alerting devices required in operational areas are documented and communicated in a style that is appropriate for the audience.A126 – BI-01P.21 – Provide document and specific references to PPE requirements for vehicle interactionsProvide document and specific references to PPE requirements for vehicle interactions – addressing lack of provided references and comment that there is a set standard in place.
BI-01S.01 Clear operator performance management expectations supported by an active and consistent performance management processLine managers ensure that safe, productive behaviours are recognised, and action is taken to correct unsafe and non-productive behaviours.A125 – BI-01S.01 – Review the approach to reinforcing requirements for compliance on wearing seat beltsReview the approach to reinforcing requirements for compliance on wearing seat belts – addressing comment – safety belt compliance = low
A127 – BI-01S.01 – Provide references and specifics related to operator vehicle use and supervisor trainingProvide references and specifics related to operator vehicle use and supervisor training. Addressing lack of provided references and comments that there are requirements in place in truck procedures
BI-01S.02 Pre-commencement and periodic medicals for mobile equipment operatorsPre-employment and periodic medicals should ensure personnel are capable of fulfilling position requirements.  A107 – BI-01S.02 – Prepare information on requirements for, and execution of medicals at MOG Prepare information on requirements for, and execution of medicals at MOG
A108 – BI-01S.02 – Review conformance of TMM Operators to eye testsReview conformance of TMM Operators to eye tests. Behavioural- operators not adhering to OMP recommendations – eye test.
BI-01S.03 Consultation and communication on safety and healthMultiple processes are in place for effective two-way communication across all organisational levels.A156 – BI-01S.03 – Provide reference and specifics around formal communications on TMM planning for safetyProvide reference and specifics around formal communications on TMM planning for safe production – addressing lack of material received prior to the validation workshop and team comments on risk assessments and planning meetings involving workers.
Required emergency checks before operation are documented and communicated in a style that is appropriate for the audience.A111 – BI-01T.01 – Review the documentation related to required emergency checks on vehiclesReview the documentation related to required emergency checks on vehicles before operation
A112 – BI-01T.01 – Update the FFP vehicle requirements to include auto-shutdowns and cabin escapeUpdate the FFP vehicle requirements to include auto-shutdowns and cabin escape. Auto shutdown not in place. Emergency escape not considered for all vehicle types
A113 – BI-01T.01 – Confirm training modules and issued licenses match vehicle emergency featuresConfirm training modules and issued licenses match vehicle emergency features to address comment BI-01T.01 check that correct license is issued 777, 930
A189 – BI-01T.01 – Review if ROPS/FOPS integrity should be included in pre-startsReview if ROPS/FOPS integrity should be included in pre-starts – addressing comments – rops/fops not on pre use checklist

Related BIBI ExpectationOFI ReferenceWorkshop Comments
BI-02D.01 Fit-for-purpose equipment selection and site use approval processes.Equipment selected for site use is fit-for-purpose and delivers safe and productive outcomes – meeting all site requirements for worker ergonomics, control integrity, matching to existing site technology, equipment performance and operating environment constraints.  A110 – BI-02D.01 – Update the FFP requirements for vehicles to include checks for the number of add-on systUpdate the FFP requirements for vehicles to include checks for the number of add-on systems installed. Too many add on systems installed leading to: -reduced visibility; -increased noise
A180 – BI-02D.01 – Confirm what learnings are coming back from tyre incidents at MOGConfirm what learnings are coming back from tyre incidents at MOG – addressing comment – Question – What learning is coming back from tyre incidents at Mogalakwena?
BI-02D.02 Standards that set minimum requirements for cabin integrity, restraints, access and escape, auto-shut downs and other relevant protective systemsEquipment selected for site use is fit for purpose and delivers safe and productive outcomes.A188 – BI-02D.02 – Source and implement consistent seat belt alarms and monitoringSource and implement consistent seat belt alarms and monitoring – addressing comments – possible engineering control to start up
A190 – BI-02D.02 – NCAP 5 rating to be reviewed and certification for rops/fops requiredNCAP 5 rating to be reviewed and certification for ROPS/FOPS required
A192 – BI-02D.02 – Confirm ISO3449 is called up in the equipment selection (for deflection limiting volume)Confirm ISO3449 is called up in the equipment selection (for deflection limiting volume)
BI-02D.04 Processes for confirming that new to site vehicles meet site specifications including vehicle lights, signage and markings (Intro to Site)All site vehicles in operating areas meet specifications for vehicle reversing & head lights, running lights, indicator and identification numbers. A142 – BI-02D.04 – Confirm references and specifics for FFP checks plus provide guidance on contactorsConfirm references and specifics for FFP checks plus provide guidance on contactors – addressing lack of material provided before team session and comments around how contractor’s proof of maintenance are sourced and maintained
BI-02D.10 Operator ergonomics are considered for controls and before introducing vehicle alarms and other aidsControl panels/devices, alarms and other aids introduced to alert the operator and / or improve situational awareness add value and support cognitive ease for Vehicle Operators.A165 – BI-02D.10 – Confirm the seat shaker trials progress ergonomicallyConfirm the seat shaker trials progress ergonomically addressing comment – Currently trialling vibration alerts in the cabin
BI-02D.21 Mobile Equipment is speed limitedWhere required mobile equipment speed is effectively governed and is designed to be tamper proofA116 – BI-02D.21 – Provide references for speed limiting of equipmentProvide references for speed limiting of equipment. Nil response received on request for comment. Not referenced in FFP vehicle specifications.
BI-02D.53 Operator display specifications are detailed for mobile equipmentOperator displays provide the information necessary for safe and productive outcomes. A173 – BI-02D.53 – Review if there is a documented standard for alarm screensReview if there is a documented standard for alarm screens – to eliminate distraction (e.g. learning from Sission incident)
A174 – BI-02D.53 – Confirm the learnings coming from visiting human factor/ergonomist are includedConfirm the learnings coming from visiting human factor/ergonomist are included in an update of the equipment display specifications
BI-02P.01 All safety and operational systems on mobile equipment are maintained.Safety and operational systems on mobile equipment are maintained to a schedule and when they breakdown. Mobile equipment with compromised safety and operational systems does not operate.A176 – BI-02P.01 – Confirm PMO3 jobs in SAP for all maintenance requirementsBI-02P.01 & BI-02P.02: Confirm PMO3 jobs in SAP for all maintenance requirements
A186 – BI-02P.01 – Confirm electromagnetic compatibility with site for all TMM technologyConfirm electromagnetic compatibility with site for all TMM technology – addressing comment – Electromagnetic compatibility, Electromagnetic interference and interoperability
A187 – BI-02P.01 – Develop and implement a No-Go defect response for CAS/PDS failuresBI-02P.01 – Develop and implement a No-Go defect response for CAS/PDS failures – addressing comment – CAS/PDS failures need to be NO-GO and monitoring improved, need to include a monitoring dashboard
BI-02P.02 Regular checking and maintenance for cabin integrity, restraints, access and escape, auto shutdowns and other relevant protective systems.The protective systems and safety related components of on-site approved mobile equipment remain functional.A171 – BI-02P.02 – Review frequency and quality of over-inspection of maintenance checksReview frequency and quality of over-inspection of maintenance checks addressing comment – Confirm documentation available around accountabilities and communication on site
A176 – BI-02P.01 – Confirm PMO3 jobs in SAP for all maintenance requirementsBI-02P.01 & BI-02P.02: Confirm PMO3 jobs in SAP for all maintenance requirements
A193 – BI-02P.02 – Air bags will only deploy at speed this means that they are not effective on siteCheck – air bags will only deploy at speeds > 60km/hr – this means that they are not effective on site (as all site speeds are below this)
BI-02P.06 Operator pre-start checks include work area, communication system, safety devices, brakes, steering, tyres and running gear.Checks are made prior to use and as required through a shift to confirm that work areas or mobile equipment that is compromised does not operate. A175 – BI-02P.06 – Develop a common standard for defect reporting across the groupDevelop a common standard for defect reporting across the group – addressing comment – Capture the training and updating of the pre-use check lists – to try and get a fail to safe system in place for the whole group (common defect management system)
A178 – BI-02P.06 – Confirm if the pre-start checks include where operators place items such as crib tinsConfirm if the pre-start checks include where operators place items such as crib tins and other heavy items in the cab
BI-02P.07 Prestart radio checksThe communications equipment required for the safe and productive operation of mobile equipment is confirmed as working. Mobile equipment that cannot communicate does not operate.A141 – BI-02P.07 – Provide reference and specific information related to radio pre-start checksProvide reference and specific information related to radio pre-start checks – addressing lack of material provided before team session and comment that there is a requirement that within 3 hours of shift start to check for pre-use
BI-02P.08 Regular checking and maintenance of key systems, brakes, steering and tyresMobile equipment functionality – with a focus on brakes (including propulsion elements on electric drive vehicles), steering and tyres on site approved mobile equipment are monitored and well maintained.  A162 – BI-02P.08 – Confirm the frequency, quality and monitoring of regular test for key systems Confirm if there are regular brake tests using go/no-go gauges, inclined brake tests and per wheel testing
A182 – BI-02P.08 – Confirm N2 requirements align with leading practiceConfirm N2 requirements align with leading practice – addressing comments – Confirm – (Sission in place and should be part of critical controls) Wheel diameters of > 25″ have a N2 fill and maintenance system in place
A183 – BI-02P.08 – Confirm or implement early warning for N2 lossConfirm or implement early warning for N2 loss – addressing comment – Are there any early warning / issues related to loss of N2 in the tyres?
BI-02P.20 Tyre hazard awareness for equipment operatorsEquipment operators are aware of tyre operational hazards and their controls. A114 – BI-02P.20 – Address short fall in training around tyre hazard awarenessAddress short fall in training around tyre hazard awareness. Comment of – Operators not aware – truck operators.
A115 – BI-02P.20 – Schedule and conduct PTOs to confirm tyre hazard awarenessSchedule and conduct PTOs to confirm tyre hazard awareness. Address comment – PTO after training on tyre hazard awareness on truck operators.
BI-02S.05 Protocols for the calibration of key measuring equipmentMeasuring and position monitoring equipment is calibrated.A102 – BI-02S.05 – Confirm existence of PMO for calibrationsBI-02S.05 Confirm existence of PMO for calibrations
BI-02S.06 New communications or technology equipment, specification, test and commissioning processThe operational deployment of improvements/new communications and technology equipment is well managed and meets all functional and performance requirements – whilst causing minimum possible disruption to existing operations A144 – BI-02S.06 – Review the management and integration of any technology pilot projectsReview the management and integration of any technology pilot projects – addressing validation workshop comment questioning how pilot projects are managed
BI-02S.30 Equipment systems data sendEquipment system data is captured and sent for monitoring and analysis e.g. tyre pressure and temperature, acceleration, braking, engine revs, speed, etc. A172 – BI-02S.30 – Allocate resources to review and report on TMM dataAllocate resources to review and report on TMM data – to address comments – Data available – not being used but manpower allocation not done

Related BIBI ExpectationOFI ReferenceWorkshop Comments
BI-03P.03 Expected routes by vehicle type are effectively communicated.All vehicle operators are aware of the routes that they are expected to travel on based on the vehicle type that they are operating e.g. segregated routes for light vehicles.A160 – BI-03P.03 – Confirm if alarms on wrong route are being reacted to and monitoredConfirm if alarms on wrong route are being reacted to and monitored. Addressing comment – Need to check if the alarms are responded to? Are they getting signal that the alarms are happening and not reacted to
BI-03P.04 Power line working distance management process.Safe working distances are always maintained between power lines and mobile equipment e.g. cranes, trucks, forklifts, etc.A133 – BI-03P.04 – Review and provide reference and specific information related to HVDS requirementsReview and provide reference and specific information related to HVDS requirements – addressing comments that there is a High Voltage Distance Separation tactic in place – but that it can be improved (reference to HME contact with electrical links bowtie).
BI-03P.05 Mobile equipment operators follow road rules and adjust based on conditions and circumstances.Mobile equipment operators follow road rules and adjust based on conditions and circumstances. A145 – BI-03P.05 – Provide reference and specific information related to TARPs for road conditionsProvide reference and specific information related to TARPs for road conditions – addressing lack of information provided prior to the workshop
BI-03S.05 Infrastructure protection – placement of barriers and/or warning devices to prevent unwanted vehicle interactionsSite infrastructure is protected from unplanned contact with mobile equipment.A120 – BI-03S.05 – Review and update/harmonise Mining and Concentrator TMPsReview and update/harmonise Mining and Concentrator TMPs. Addressing comment – Mogalakwena mine TMP require updates the mining side with the concentrator TMP
BI-03S.20 Speed and other operating parameter data sendEquipment operating data (speed, travel paths, engine performance/load, etc.) is captured and sent for monitoring and analysis.A105 – BI-03S.20 – Confirm status of off-vehicle capture of monitoringConfirm status of off-vehicle capture of monitoring. Are speed and other driver behaviour metrics captured at MOG? If they are – what is documented as a requirement to review this output and generate reviews of TMM operator behaviour, short term planning performance and/or supervisor monitoring of TMM movements.
BI-03T.10 TARPs prepared for unwanted conditionsTrigger action response plans (TARPs) are put in place for conditions which will impact on the site’s ability to achieve safe movement of mobile equipment. A103 – BI-03T.10 – Confirm the connection between the TARPs and the Emergency Response PlanConfirm the connection between the TARPs and the Emergency Response Plan.

Related BIBI ExpectationOFI ReferenceWorkshop Comments
BI-04D.21 Road design guidelines specify minimum parking area requirementsParking area designs are fit for purpose. Parking areas are constructed and maintained to meet site requirements.A158 – BI-04D.21 – Provide references and specific guidance related to establishing parking areasProvide references and specific guidance related to establishing parking areas – from lack of material provided and comments on hard park access in the session.
A159 – BI-04D.21 – Confirm arrangements for compliance checks after construction of parking areasConfirm arrangements for compliance checks after construction of parking areas – addressing validation team comments about an unknown status for confirming there are QA/QC and compliance checks after building parking areas.
A167 – BI-04D.21 – Confirm MOG design standards for parking are leading practiceConfirm MOG design standard is similar to other Anglo pits – similar to Sission (drive through parking with humps for front and rear wheels). Review if there are specific requirements needed for trailer parking without CAS and other movable plant such as toilets etc.
BI-04P.01 Vehicle interactions are considered as part of the short-term planning processesMobile equipment interactions and operating requirements are always considered when approving, planning and scheduling work.  A119 – BI-04P.01 – Review how short term planners can include interaction considerationsReview how short term planners can include interaction considerations. Addressing comment – In place but need to be management eg boom gates and traffic lights
BI-04P.02 Around vehicle inspection or use of spotters to identify hazard before movingThere are no unplanned vehicle to person or vehicle to vehicle contacts on first movement after parking.A151 – BI-04P.02 – Implement a system for gathering and analysing pre-use checksImplement a system for gathering and analysis pre-use checks – addressing team comment around gathering of pre-use checks. This may also include reviewing an electronic (rather than paper-based) system.
BI-04P.06 Protocols for approaching and accessing mobile equipmentApproaching and accessing equipment follows defined processes that limit the potential for an unwanted interaction between vehicles and/or pedestrians.A134 – BI-04P.06 – Provide reference and specific information related to approach and access of HMEsProvide reference and specific information related to approach and access of HMEs – addressing lack of references provided and comments related to 50/30 (or is it 60/30) rule.
BI-04P.08 Pedestrian working in operational area communications protocolPersonnel working on the ground in mobile equipment operational able to effectively communicate.A155 – BI-04P.08 – Update and formalise procedures for pedestrians working in operating areasUpdate and formalise procedures for pedestrians working in operating areas – addressing team comment that communication needs some attention
BI-04P.10 Specification covering escorting requirementsVehicles that are not approved for unrestricted site access are escorted. Site escort requirements are clear and deliver safe and productive outcomes.A147 – BI-04P.10 – Confirm if escorting and licence requirements are detailed in 10 min InductionConfirm if escorting requirements are detailed in 10 min Induction – addressing comment to confirm if escorting requirements are included in detail in the 10 minute induction and assessment process. Also review putting place a formal process for checking license of drivers of vehicles under escort.
A148 – BI-04P.10 – Confirm if signage or decals needed for Escort vehicleConfirm if signage or decals needed for Escort vehicle – addressing team comment questioning decals
BI-04P.12 Established requirements for parking and resting in vehiclesParking and leaving parked positions does not result in mobile equipment interaction incidents. A152 – BI-04P.12 – Develop and implement a system for resting in cabinsDevelop and implement a system for resting in cabins – addressing a comment that operators do rest in vehicle with aircon on (machine idling) – but they do not always do a walk around prior to re-starting movement.
BI-04P.13 Established requirements for approaching parked mobile equipment in operational areas.Personnel approaching a vehicle parked in operational areas are not endangered by an unexpected vehicle movement. A153 – BI-04P.13 – Provide reference and specific requirements for 50/30 proceduresProvide reference and specific requirements for 50/30 procedures – addressing team comment around the start/stop procedure 50/30 rule.
A154 – BI-04P.13 – Define refresher requirements for understanding of HME approach proceduresDefine refresher requirements for understanding of HME approach procedures – addressing team comment about the requirement to provide guidance on refresher times.
BI-04P.14 Positive communication protocol for passing or moving close to a vehiclePassing of vehicles is well managed and based on positive communications. A135 – BI-04P.14 – Provide reference and specific information related to pos comms – and review technologyProvide reference and specific information related to pos comms – and review technology – addressing lack of information provided and comments including the changes in radio channel and the congested radio network on site.
BI-04S.04 Access barrier performance – regular inspection and maintenance of barriers for access – boundary fencing and work area barriersAccess to operational areas for personnel and mobile equipment is well managed. Barriers are in place that prevent unauthorised access including security (for site) and sentries/physical barriers (for blasting and other high consequence activities (including remotely operated mobile equipment) on site).  A146 – BI-04S.04 – Review site fencing and considerations around pedestrian access to siteReview site fencing and considerations around pedestrian access to site – addressing comment that pedestrians access site where no fences exist.
A185 – BI-04S.04 – Update required inspection frequency of boundary fencesUpdate required inspection frequency of boundary fences – addressing comment – More frequent inspections required
BI-04T.01 Ceasing Operations Procedure – significant interaction threatsSites should have cease operations processes (Trigger Action Response Processes/Plans) in place for situations for where significant interaction threats have the potential to develop.A149 – BI-04T.01 – TARP for lightning to develop and implementTARP for lightning to develop and implement – addressing team comment on lightning TARPs being needed to be developed and then have people trained and assessed in them.
BI-04T.20 Proximity detection, permission lines, alerts, advice, and intervention.When proximity detection monitoring/autonomous systems are fitted, they have operator alert, advice and intervention capabilities that meet site functional and performance requirements. A136 – BI-04T.20 – Confirm CXS deployed technology meets site requirementsConfirm CXS deployed technology meets site requirements – addressing comments that the intervention options are not deployed and CAS System Operating at level 7 No intervention can be improved to level 9 – NB – current system has limitations
A137 – BI-04T.20 – Review mine and equipment design requirements impacting available operating spacesReview mine and equipment design requirements impacting available operating spaces – addressing comments 1. Space limitation effects distance between machines (design not adequate), and 2. HVDS Truck + scaling rigs

Related BIBI ExpectationOFIOFI Description
BI-05D.02 Clear accountabilities for planners are included in comprehensive and site relevant road design guidelines and traffic management plansSite road design guidelines and traffic management plans identify specific accountabilities for planners.A170 – BI-05D.02 – Confirm documentation available around accountabilities and communication on siteConfirm documentation available around accountabilities and communication on site
BI-05D.03 Effective contractor management processesSite contractor management processes are effective. A143 – BI-05D.03 – Review how subcontractors gain access to site and use HMEs on siteReview how subcontractors gain access to site and use HMEs on site – addressing comment on access arrangement for subcontractors
BI-05D.04 Position descriptions that specify expected supervisor performanceSupervisor performance descriptions.A128 – BI-05D.04 – Provide references and specific information on training around supervisor expectationsProvide references and specific information on training around supervisor expectations – to address lack of provided information and comment that supervisors have an understanding of role descriptions.
A179 – BI-05D.04 Confirm if MOG has specific training and add in the training elementsConfirm if MOG has specific training and add in the training elements – all vehicle operators and supervisors should understand how to load vehicles
BI-05D.09 Change Management ProcessApplied and effective change management processes are in use at the operating site.A164 – BI-05D.09 – Confirm updates for MoC training occur to meet requirementsConfirm the training updates for MoC occur and achieve the goal of consistent improvement of controlling changes (computer based system with web interface). Intent is to automate both approval and communication (but this is still pending).
BI-05D.11 Emergency PreparednessThe site has a formal approach for emergency preparednessA194 – BI-05D.11 – Confirm the baseline risk assessments are applied to determine / set up the approachConfirm the baseline risk assessments are applied to determine / set up the approach to ER and first aid at Mogalakwena
A195 – BI-05D.11 – Review the Emergency Preparedness drills in place for VI incidentsReview the Emergency Preparedness drills in place for VI incidents – addressing comment – What about an emergency response test protocol or drill within the ER Plan that addresses a suite of unwanted VI emergencies
A196 – BI-05D.11 – Confirm if audit and improvement process for ER is in place at MOGConfirm if Mogalakwena has an audit and improvement process in place for emergency response (check in with Jacob Boshielo)
A197 – BI-05D.11 – Confirm that first aiders receive appropriate epi-pen trainingConfirm that first aiders receive appropriate epi-pen training (when and how to use and contraries to use)
BI-05D.99 There is a documented site Traffic Management PlanMobile equipment management is well coordinated, practical and integrated with routine operational and business processes.A117 – BI-05D.99 – Review how to apply change management to TMP changesReview how to apply change management to TMP changes. Updates on TMP not aligned to standard (change management)
A118 – BI-05D.99 – Review if TMP requirements should be included in regular auditing programReview if TMP requirements should be included in regular auditing program. Addressing comment – external audits not applicable (or not in place currently).
BI-05P.02 Site change management process apply to changes in equipment, road networks and traffic flowsApplied and effective change management processes are in use at the operating site and these apply to:

·   Changes in road networks and traffic flows
·   The introduction of new models and types of mobile equipment and components e.g. introduction of electric battery powered equipment
A117 – BI-05D.99 – Review how to apply change management to TMP changesReview how to apply change management to TMP changes. Updates on TMP not aligned to standard (change management)
BI-05P.03 Consultation and communication on traffic management planMobile equipment operators and other involved personnel contribute to a safe and productive mobile equipment operations site. A169 – BI-05P.03 – Implement critical control monitoring on Isometrix for TMM and SME to make it legalImplement critical control monitoring on Isometrix for TMM and SME to make it a legal inspection on a set frequency
BI-05P.03 Consultation and communication on traffic management planA184 – BI-05P.03 – Implement job cards for updating and communicating the TMPImplement job cards for updating and communicating the TMP – addressing comment – No job cards in place to update the traffic management plan
BI-05P.05 Skilled and experienced personnel are accountable for determining the operating parameters for mobile equipment useMobile equipment is designed/selected to meet operational requirements (people, infrastructure and site) and operates within its design parameters A122 – BI-05P.05 – Review the data flow from weightometers to operatorsReview the data flow from weightometers to operators. Addressing comment – scoreboards installed on haul trucks to assist with weight to calibration? working? only done when issue is seen
A123 – BI-05P.05 – Review truck bowl choice on 930 E-4 trucksReview truck bowl choice on 930 E-4 trucks. Addressing comment – 930 E-4 design load 290t. Target load 320t. realign light weight bowls to allow
A124 – BI-05P.05 – Review requirements for documenting pavement specificationsReview requirements for documenting pavement specifications. Addressing comment – Pavement shape – no specs currently – surface yes pavement no – Concrete slab spec/design
A181 – BI-05P.05 – Confirm documentation for load monitoring is available to designers and operatorsConfirm documentation for load monitoring system provides operators with warning of carry back occurring
BI-05P.06 Structured line and functional support for supervisors when applying site performance management processesAll supervisors are supported so they can effectively apply site performance management processes.A129 – BI-05P.06 – Provide references and specifics related to supervisor coaching and mentoringProvide references and specifics related to supervisor coaching and mentoring – addressing lack of provided material and comments that there is ER process + coaching, coaching courses and ER Record keeping
BI-05S.02 Effective incident reporting, investigation with effective corrective actionsIncident investigation is a business improvement process for identifying and solving issues that compromise site safety and productivity.A106 – BI-05S.03 – Review how priorities are set for conducting and communicating actions from incidentsReview how priorities are set for conducting and communicating actions from incident investigations. Delayed reporting to site personnel due to delayed investigations
BI-05S.03 Hazard and incident reporting process that generates value adding corrective actionsThe site has an effective and well used hazard and incident reporting process.A106 – BI-05S.03 – Review how priorities are set for conducting and communicating actions from incidentsReview how priorities are set for conducting and communicating actions from incident investigations. Delayed reporting to site personnel due to delayed investigations
BI-05S.06 Comprehensive fitness for work process includes alcohol and other drugsSite requirements that all employees, contractors and visitors are fit for duty (unimpaired) while in the workplace. A109 – BI-05S.06 – Develop a process for collecting FFW test results as a permissive for vehicle startDevelop a process for collecting FFW test results as a permissive for vehicle start. Not monitored in shift and in equipment
BI-05S.07 Senior management review, update, and confirm the Traffic Management Plan as being fit-for-purposeSenior managers periodically confirm that the site Traffic Management Plan (or equivalent) is fit-for-purposeA121 – BI-05S.07 – Review the process of communicating TMP requirements at every approved changeBI-05S.07 – Review the process of communicating TMP requirements at every change. Addressing comment – Formal comms not circulated for all changes.

1. Business Input Gap Type2. Relevance for VI Control Stabilise, Restore, and Enhance Planning3. General Comments on Performance Monitoring, Digitisation and Detecting Drift
Inadequate ExpectationReview CFw Business Inputs and their expectations.

Identify those that are not relevant for Mogalakwena operations.

Review work processes associated with these and modify, or cease, the work.
Unnecessary site processes may be developed and implemented based on a local interpretation of an inadequate BI Expectation.

Subsequent performance monitoring of unnecessary work processes wastes resources and provides an inaccurate drift signal about the status of VI Controls.

Drift detection and response is inconsistent because the BI expectation can be interpreted in multiple ways
Inadequate SpecificationPrepare detailed specifications where there are gaps.

In the revised specification, consider implementation, integration with existing operational processes, and how the work process performance can be monitored.

Operational implementation and performance monitoring of a work process will be inconsistent if a specification is unclear.

Some business inputs can be well implemented and adequately monitored e.g. road or roadway construction and maintenance that is undertaken by experienced personnel.

However, if there is a personnel change, without an adequate specification, there is no reference to check that standards are being maintained.
Without an adequate specification, drift detection and response are inconsistent because the specification can be interpreted in multiple ways.

If there is a measurable specification (performance measure) for a work process, then adverse excursions can be detected and addressed within an appropriate timeframe.

As businesses and operating sites develop digital capability, many aspects of performance drift and response can be semi-automated.

This transition has multiple benefits that include providing short-cycle feedback to equipment operators, increasing the span of management for supervisors, and enhancing business analytics.
Inadequate ImplementationWhere there are gaps in the implementation of Mogalakwena work processes, consider if the work process is:

·  Required
·  Well designed and clearly specified
·  Integrated into operations

Confirm why current work process implementation is inadequate.
Without adequate work process implementation consistent and stable drift detection and response is unachievable.

However, if the work process has a measurable specification, then a review of performance status will immediately highlight inadequate Implementation.
Inadequate MonitoringSuggestions to improve work processes without confirming how they will be monitored should be challenged at the planning processes.

To be an adequate VI Control, a work process must have performance measures and be able to be monitored.
A fit for purpose and well-designed work process that has been operationally integrated can still be inadequate if its performance cannot be monitored i.e. there if there is poor or nil performance management signal.

Detecting drift from a work process requires both a signal and a reference specification.

Without monitoring, drift is dependent on the judgements of people and may not be detected until the work process catastrophically fails.

Further, for the signal to inform local, supervisory or system actions then details of the expected work process performance must be specified at for each the level. This approach supports the development of User Requirements.

Without monitoring data, then all decisions about work process design and implementation improvements are subjective.

What Your People Said

Workshop comments