Technology, Productivity, Safety and the Future

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Technology, Productivity, Safety and the Future
Are You Ready?
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What Are We Going To Talk About!

• Current Products
• Near Term Products
• Long Term Products

Safety, Productivity and Technology
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Caterpillars Technology Approach
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Achieving Significant Production Increases
Mines must focus on People, Processes and not
just the Product in isolation
Production
Technology
People
Process
Product
Safety
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Cost
Minimizing Total cost per ton
Ton
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Cost Per Ton Sensitivity
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MineStar Fleet Commander
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Labor- Operator Management

• Employee Information
• Crew
• Shift
• Roster
• Workgroups
• Licensing
• Absences\Overtimes
• Shift Change Allocation
• Operator Notes
• Incidents, Performance Notes, etc

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Labor-Shift Change

• Operator Allocation
• Preferences
• Licenses
• Available Machines
• Over Time/ Absences
• Tie Down Destination
• Maximize Machine Uptime
• Transportation Vehicle

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Labor-Operator Performance

• Crew
• Crew Score Cards
• Truck
• Assignments followed\missed (operator, average
  crew, average site)
• Abuses (operator, average crew, average site)
• EFH Comparison (operator, average crew, average
  site)
• Spotting comparison (operator, average crew,
  average site)
• Operator Delay (operator, average crew, average
  site)
• Road Segment Speeds (operator vs Truck class)
• Road Segment Gears
• Last hour EFH Tons compared to previous hour
  tons
• Shovel
• Load accuracy (10-10-20)
• Dipper count per Truck class by Loading Tool
  Class (operator, average crew, average site)
• Operator Delay (operator, average crew, average
  site)
• Load Time by Material by Tuck Class cy Loading
  Tool Class (operator, average crew, average site)
• Load Placement
• Aux
• Time Management

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Labor-Training
MineStar
MineStar
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Assignment

• Production Plans
• Without Production Plans MineStar tries to get
  the most tons
• Trucking Indicator
• Dynamic Travel Times
• Dynamic Final Roads
• TKPH
• Blending
• Regions
• Dynamic Loading Efficiencies
• Scheduled Assignments
• Fueling

New version of MineStar showing 5
efficiency Improvement with new Assignment
Engine!
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Production-Payload Management

• Load Factor
• Pit
• Cut
• Bench
• Material
• Etc
• Nominal Tonnage
• Actual Tonnage
• 2nd Gear Reweigh on VIMS
• Loading Tool kpi through peer to peer
  communication
• Real Time Payloads
• Historical histograms
• Next Dipper
• Real Time Alarms (10-10-20)
• Under Loaded
• Over Loaded (can still Travel)
• Extremely Over Loaded (Dump Immediately)

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Production- Time Break Down

• Site Customized Time Model
• Total
• Delays
• Operating Time
• Utilization
• Down Time
• Availability
• Standby
• Delays
• Custom names and Categories
• Immobility Detection
• Email nonfiction
• Assignment Delay or Not

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Production- Dashboards
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MineStar Future

• Current development activities
• 3rd party interface pulling machine health data
  from non-Cat machines
• Auxiliary equipment assignment Enhanced 3D
  visualization
• Merged office software (METSmanager, CAESoffice,
  Machine Manager MineStar)
• Usability analysis
• Autonomy Haulage and Drills
• Development Focus is always on
• Functionality
• Technology
• Cost of Ownership

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Aquila Drill System-Production

• Industrys most comprehensive drillmonitoring
  system
• Displays and records six drill variables
• Depth and penetration rate
• Rotary speed
• Pull-down pressure
• Bailing air pressure
• Rotary torque
• Generates operator practice andproduction
  statistics
• Operator Tracking
• Time Breakdown Model

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Drilling-Guidance

• 3D drill and bit positioning
• Automatically adjusts hole depths basedon
  measured collar elevations
• Stakeless drilling
• Reduced surveying
• No layouts or pre-blast pick-ups
• Avoidance Zones
• Hot holes
• High walls
• Peer to Peer Communications

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Drilling-Strata

• Real-time recognition of varying rock properties
• Fractured vs. intact zones
• Coal vs. waste zones
• Blastability Index guides explosives loading and
  design
• Where explosive energy is required
• How much
• Which products

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Consumables-Drill

• Reports on
• Number or revolutions each consumable
  experiences
• Actual drilling minutes
• Actual drilling footage
• Cumulative energy for each consumable

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Caterpillar CAES Computer Aided Earthmoving System
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Grade Control

• Pad Construction
• Bench Control
• Dump Control
• Drainage
• Crowns
• Ramps
• Roads

• Typically 1-2 lost cycles per shift because of
  poorly constructed haul roads, and uneven benches
• Proper slope aids in water run off
• Can help optimize tire life

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CAES For Support Equipment

• Machines
• Dozers
• Rubber Tires
• Graders
• Water Trucks
• Scrapers
• Fuel Trucks
• Time Management (Time Break down model)
• Activities
• Delays (Down Time)
• Utilizations
• Availability
• Job Codes
• Allocating the Dozers Time toward the Mill vs
  Production

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Safety

• Site Aware
• Machine to Machine Position Updates-Confirm
• Operator Identified issues Broadcast to Machines
• Avoidance Zones
• 2D
• 3D
• Safety Messages
• Broadcast Messages
• Login Safety Reminder Message
• Mayday Buttons
• Safety Checklist
• Machine Licensing
• Machine Login ID
• Real Time Event Messages

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Reclamation

• Maximizing Efficiency
• Working to planed design
• Minimizing re-handle
• Operational continuity across shifts and operator
  exchanges
• Optimizing tolerance
• Moving the least amount of materials while still
  achieving the minimum required topography
• Maximizing usage of topsoil

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Ore\Material Control Automatic Identification

• CAES HEX
• Import from 3rd Party
• Exporting to/from MineStar
• Automatic Identification
• Grade Blocks
• Material zones
• NO staking

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Cat Mining Technology Sites Worldwide

• Mining Technology products are currently
  operating in more than 100 mine sites around the
  world
• More than 700 High precision systems (CAES
  AQUILA)
• MineStar Sites
• Newmont Twin Creeks Nevada
• Newmont Carlin Nevada
• Newmont Phoenix Nevada
• Arch Coal Black Thunder Wyoming
• Boliden Aitik Sweden
• El Tesoro Chile
• Oceana Gold (Macraes) New Zealand
• BHPB Cerra Matoso Colombia
• Barrick - Cowal Gold, Australia
• GoldCorp Porcupine Creek, Canada
• Xstrata Glendell, Australia

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Improving Our Product Safety
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Sustainable Solutions through Mining Equipment
Design and Development

• Topics
• Design Processes
• Health Safety
• Partnering with the Industry

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Caterpillars Product HSEC Process
Will spend hundreds of M over the next 5 years
just for Mining related SD solutions
Safety Design Guide
Voice of Customer, Industry, Dealer
Hazard Identification and Resolution
International Standards and Regulations
New Technology Introduction New Product
Introduction Continuous Product Improvement
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Earth Moving Equipment Safety Round Table
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Sustainable Solutions through Mining Equipment
Design and Development

• Topics
• Design Processes
• Health Safety
• Partnering with the Industry

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Safety Access Systems
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Large OHT Powered Access System - Project
Objectives

• Functional requirements
• Truck integrated system that can be sold as an
  attachment that is plug-in ready at the dealer
• The system has to give warning to the operator if
  the stairway is not in the up position.
• Review schedule
• Testing to start by the end of May
• Production dates
• 793F Sep 1
• 797F Oct 1
• 789D at first production
• 785D we are working on the introduction date
• C/D truck model retrofit package being worked

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LOHT Powered Access System - Design Features

• The system is hydraulically controlled with
  actuation points at the top and ground levels
• The system gives a warning to the operator if the
  stairway is not in the up position
• The system will not function unless the truck is
  park
• Handrail design is designed to eliminate pinch
  points

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LTTT Powered Access Ladder

• Powered access ladder was designed to provide
  operators with an access solution for Large Track
  Type Tractors
• Utilizes the machine power train system to
  operate, no separate hydraulic reservoir
• Integrated into the machine systems to provide
  notification that the ladder is down if the
  machine is put into gear
• Momentary activation location requires that the
  operator observe ladder operation

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LTTT Powered Access Ladder
Stowed Position
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Large TTT MG Access Systems

• Large Track Type Tractor Powered Access Ladder
• D 11T
• Accepting orders now
• D 11 R
• Under review
• D 10
• Under development, anticipate 2010 availability
• Motor Grader Access System
• In final design review now
• Field follow - November 2009
• Production March 2010

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LH Platform, Walkway and Ladder Assembly
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Access Platform Emergency Egress
Fender outside boundary
Fender outside boundary
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Access Systems
Underground Trucks Loaders
Wheel Dozers
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Caterpillar Integrated Object Detection System
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Safety - Collision Scenarios

• Mine Site Collision Data
• (Voice of Customer)
• Collision Detection Forum
• Hundreds of accidents investigated across four
  global customers
• 172 accidents investigated in depth initially
• 14 accident scenarios developed

Collision avoidance ranked 3 by Customers
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Product Design System Function
Integrated Object Detection System
The current sensor layout consists of
Front Medium Range
Rear Medium Range
Side Medium Range

• Front
• 2 medium range radars
• 2 short range radars
• Sides
• 2 medium range radars per side
• Rear
• 2 medium range radars
• 2 short range radars

Rear Short Range
Front Short Range
Side Medium Range
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Product Design System Function
Touch camera image to full screen
Camera Selection Hat switch
Full screen camera
Change Screens (Main, Config, Diag)
Touch screen navigation buttons
Brightness (up/down, day/night toggle)
An audible warning sounds that is perceptible
above ambient cab noise, when operator neglects
correct procedure.
Diagnostics and System Status

• Quadrants around truck are touch screen hot
  spots to select camera

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Remote Control Track Type Tractor
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D10T/D11T Basic RC

• Over-the-shoulder RC console
• Line-of-sight operation
• 2 Units on Field Test

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Remote Control Operator Station

• 1 System Currently Scheduled for Field Testing at
  8/7/2009.

• 4 Camera Tele Remote
• Audio Feedback
• Remote Tractor Dashboard
• Integrated Avoidance Zones
• Caterpillar operator chair with Integrated
  Joysticks

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D10T D11T RCOPS Trailer
2 units awaiting full commissioning (8/7/2009)
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RCTTT Integration with CAES

• CAES provides avoidance zones functionality for
  RCTTT
• Available on both basic line-of-sight system
  RCOPS
• Stops machine when it gets too close to
  configured structures
• Stops machine when trying to leave work zone

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Working at Heights
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Safety - Working at Heights

• Grouped, Ground Level Service Points
• Engine, Hydraulic, Powertrain
• Battery now in Front Bumper
• No PM Service items on RH deck of trucks

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Safety Serviceability Working _at_ Heights

• Ground level service
• Filters
• Batteries
• Air system service
• Autolube
• Engine oil sight glass

793D
793F
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Safety - Ground Level Maintenance

• Fuel Add Level
• Windshield Fluid Add Level
• Engine Oil Add Level
• Engine Coolant Add Level
• Implement Oil Add Level
• Transmission Oil Add Level
• Steering Oil Add Level
• ORS Add Level
• Auto-lube Add Level
• Messenger
• Start Switch
• VIMS Connector
• Laptop Power Port
• ET Connector
• Light Toggle Switch
• Engine Oil
• Engine Coolant
• Implement Tank Hydraulic Oil
• VIMS Key Switch (Not Shown)

993K
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Safety Ground Level Isolation (Lockouts)
993K
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Safety - Harness Tie-Offs

• Next generation of machines will have tie off
  points where applicable
• Inspection and weld repair procedures
• Operation and Maintenance Manual information
• Design philosophy for working at heights

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Ground Level Maintenance
Underground Trucks
Coolant
Hydraulic
Engine Oil
Transmission
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Speed Limits For Underground Trucks

• Limit speed in high traffic areas
• Achieve maximum surface speeds while
  maintaining the underground speed limit for
  safety
• Easily adjustable speed limits

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Equipment Noise - Sound Design Guidelines
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Operator Fatigue - Improved Cabs (OHT, TTT, LWL)

• Quieter
• More space
• Improved ergonomics
• Greater Visibility

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Burning Issues
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Customer Mine Operator Noise Data
Occupational exposure Limit (85 dB)
Noise is above limits and will cause damage to ear

• Reasons for High Cabin Noise
• Two way radio and FM radio operating on high
  volumes at the same time

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Goal Statement

• Identify high potential operator noise exposure
  reduction design options for large mining
  machines based on customer's operating conditions
  and key machine noise sources
• Analyze machine noise under working conditions to
  better define critical conditions contributing to
  operator noise exposure (work cycles, machine
  applications, environmental conditions, etc.)
• Leverage from operator noise measurements on
  D10T/D11T, with cab viscous mounts to understand
  its impact on structure borne noise.
• Understand radio (AM/FM CB radios) noise issue
  and validate the solution on machine
• Conduct 793D-LMT operator noise measurements to
  study the new acoustic materials inside the cab,
  such as membrane absorber, micro perforated
  materials (to reduce the noise in the low
  frequency range 60 - 200Hz)

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Sustainable Solutions through Mining Equipment
Design and Development

• Topics
• Design Processes
• Health Safety
• Partnering with the Industry

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www.Safety.CAT.com

• Human Safety Information
• PPE, Warning Labels
• Service Technician Safety
• Toolbox Talks
• Machine Operation / Safety
• Walk around Inspections
• Maintenance Checklists
• Pre-start, Operating Tips
• Safety Sections from OOM

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Health Safety - Operator Fatigue

• Reviewed of state of the industry for operator
  drowsiness detection technologies.
• White paper available free of charge at
  SAFETY.CAT.COM

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Health Safety - Operator Fatigue

• Managing a Mining Lifestyle DVD
• Caterpillar initiative developed with shift work
  experts to educate and increase awareness for
  those in mining industry.

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Viewpoint
Highlighting our focus on continuous improvement
projects with customers
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CATERPILLAR CONFIDENTIAL GREEN
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Technology Summary

• Technology
• Are you afraid of it?
• Do you have a site champion?
• Do you have a 20,000 ft vision?
• Do you have a short term and long term strategy?

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Productivity Summary

• Tons per day gets you through today!
• Cost/ton gives you a job next year!
• Correctly implemented technology provides both!

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Safety Summary

• Unless you provide a safe place to work,
  everything else is irrelevant!
• Look at every piece of new technology through
  safety glasses!
• Technology, properly implemented will deliver a
  safer mining operation!

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Caterpillars Technology Approach
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QUESTIONS ??
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Thank You!