Tuesday, 25 February 2020
Technology Trial Improved Productivity by 5%

Technology Trial Improved Productivity by 5%

This was originally published by iVolve.

Challenge

A global lime and limestone company wanted to increase productivity and reduce cost, and realised that to do that they needed to move away from their paper-based system and start measuring actual numbers with a Fleet Management System (FMS). The time between collecting data and analyzing it was taking upwards of 18-24 hours, too long and inaccurate for any significant improvements to be made. iVolve’s FMS solution was installed as a 2-year pilot program at a limestone mine in the USA to demonstrate how a large-scale FMS collecting production and maintenance information from across the site could improve the fleet metrics and deliver business value. 

Method

A baseline level of performance was recorded prior to the iVolve deployment. The iVolve FMS was then installed on a CAT 992 wheel loader, two CAT 990 wheel loaders, and four CAT 777 trucks.

Operators were shown how the iVolve system gave them instant feedback in the cab so they knew they were getting maximum productivity on each load. Dispatch and management were shown how to use the iVolve system dashboards and reporting functionality to plan, oversee, and report on each shift to maximise efficiency.

"When the system went down and the operations didn't have feedback, I saw our tonnage fall from 99 tons to 95." - Mine Engineer.

Findings

Significant cost reductions were made at site over the seven months (calculations based on standard shift calender time), as illustrated in the table below. 

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The potential productivity figure was based on the site’s ability to make further improvements to productivity and cycle times. Before the iVolve FMS was installed, the tonnage was averaging at 95. After installation, the target was set at 105 tons. At the time of calculation, the payload had increased to 99 tons, leaving room for further improvement.

The iVolve FMS was initially scoped to have a return on investment in 2 years. Actual return on investment was achieved in under a year. 

To download the full white paper, which includes further information about additional benefits and solution, please visit iVolve's website.

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