Publication: OPTIMIZACIÓN DE LA VARIABILIDAD DEL SUMINISTRO DE MINERAL HACIA LAS PLANTAS CONCENTRADORAS EN GRAN EMPRESA MINERA
Date
2016
Authors
STURZE ALARCÓN, IAN
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Abstract
Las correas transportadoras que envían material a las concentradoras son alimentadas por una configuración de cuatro fuentes distintas y separadas por grandes distancias, esto se traduce que ante un imprevisto en cualquiera de las fuentes de mineral impacta sobre la carga de la correa, pero no necesariamente de forma inmediata por lo que hay un desfase dependiendo en donde se produce la falla. Esto genera una alta variabilidad en la carga transportada.Para entender la situación y la raíz de los problemas, se comienza por entender la configuración del sistema de chancado y correas, y se visita de forma habitual a distintos operadores de chancado para conocer los problemas regulares a los que se enfrentan, como se resuelven, cuanto tardan en resolverse y cómo impactan al sistema.Se consiguen los registros del pesómetro de la correa overland minuto a minuto de todo el mes de Junio, esta data incluye información de mantenciones, ensayos, quiebres operacionales y fallas. Ante la gran cantidad de variables se decide evaluar la situación de mayor interés, “el desempeño durante la operación normal”. Para esto se proponen varios tipos de muestreo y finalmente se opta por escoger un horario pertinente para el turno día y para el turno noche. De esta forma se grafica la media y mediana de la carga de cada día durante sus 24 horas, con esto se visualiza que los horarios de 16:30 a 19:30 durante el día, y de 22:00 a 01:00 durante la noche son menos susceptibles a los quiebres operacionales como colaciones o cambios de turno. Antes de continuar con el desarrollo se debe filtrar la información obtenida correspondientes a mantenciones y fallas aguas abajo de la correa overland.Se busca la distribución más adecuada, al no ajustarse correctamente a ninguna, se proponen dos análisis en paralelo, uno específico en el cual se busca segregar la información según criterios relevantes para poder facilitar el estudio, y un análisis general en el cual se pueda interpretar el desempeño general percibido por la empresa.En el análisis específico, se propone segregar la data en base a los turnos de operadores, jornada día o noche y horario administrativo, ya que un ANOVA demostró que estos factores son relevantes se procede a separar la data, y debido a unos casos de multimodalidad se consiguen 23 subconjuntos, los cuales son transformados según cada caso para normalizar y estandarizar. Posteriormente, se realizan análisis de capacidad para evaluar desempeños, para esto fue necesario definir un desviación estándar objetivo.Con esto se consigue identificar que operadores trabajan mejor o peor en que instancias y en qué medida, logrando así conocer cuando se requiere poner mayor atención a la labor de los operadores, coordinación con despacho, etc.Para el análisis general se busca aquella distribución que tenga el menor índice de Anderson-Darling y el mayor coeficiente de correlación, consiguiéndose así una curva a la cual asociar el análisis de capacidad.Para la estimación del beneficio se propone un caso ideal en el cual se corrigen las fallas alcanzando un aumento de mineral enviado de un 11,58%, este factor deberá ser castigado de forma que se adecue al impacto de cada alternativa propuesta.
The belt conveyors that deliver the crushed ore to the concentration plants, are fed by an arrangement of four different sources, and separated by long distances, this means that if a failure occurs at any of the sources, it will affect the load in the belt conveyors, but not necessarily it means an immediate effect so there is a gap depending where the incident occurred, these produces a high variability in the delivered load.For a better understanding of the situation and the troubles the comprehension of the arrangement of crushers and belt conveyors is needed, also the crusher´s operators are visited on a weekly basis for a grasp of their most common operational troubles, how they deal with them and how it affects the production.The record of the belt conveyor´s weightometer are obtained, this information covers minute by minute the whole month of June, which includes the influence of maintenance, tests, operational breakdowns and failures. Given the large number of variables, it´s decided to evaluate most relevant situation, “the performance during normal operation”. For this, several sampling methods are proposed and ultimately a sampling is chosen in which a suitable lapse is selected for the day shift and another for the night shift. Thereby, the median and the average of the load of each day are plotted for the 24 hours, this way it´s shown that during 16:30 to 19:30 for the day shift and from 22:00 to 01:00 for the night shift, there is the lesser chance of occurrence for the operational breakdowns as shift change or collation. Before continuing with further analysis, the information obtained must be filtered from the influence of maintenance and failures downhill from the belt conveyor.The most adequate distribution is looked for the database obtained, but no good fit is achieved, therefor two parallel analyses are proposed, a specific one in which information will be segregated by relevant criteria in order to grasp a better understanding inside the data; and a general one in which performance can be read into as perceived by company.In the specific analysis, the data is segregated by operator´s groups, day and night shifts and administrative schedule, since an ANOVA proved that those were relevant factors, and due to some cases of multimodality 23 subsets are obtained, which were respectively transformed to normalize and standardize. Later on, a capability analysis is made for each one to evaluate the performance, for this a goal had to be set for the standard deviation.With this, is achieved an identification of which operator works best or worse in which instances and in which measure, knowing when attention is needed for the operators, coordination with dispatch, etc.For the general analysis it´s looked for the distribution with the lower Anderson-Darling index and the highest correlation coefficient, thereby attaining a distribution to associate the capability analysis.For the estimation of the benefit, an ideal case is proposed in which all failures are corrected achieving an increase in the ore delivery of 11.58%, this factor must be lowered so that it suits the impact of each alternative proposal.
The belt conveyors that deliver the crushed ore to the concentration plants, are fed by an arrangement of four different sources, and separated by long distances, this means that if a failure occurs at any of the sources, it will affect the load in the belt conveyors, but not necessarily it means an immediate effect so there is a gap depending where the incident occurred, these produces a high variability in the delivered load.For a better understanding of the situation and the troubles the comprehension of the arrangement of crushers and belt conveyors is needed, also the crusher´s operators are visited on a weekly basis for a grasp of their most common operational troubles, how they deal with them and how it affects the production.The record of the belt conveyor´s weightometer are obtained, this information covers minute by minute the whole month of June, which includes the influence of maintenance, tests, operational breakdowns and failures. Given the large number of variables, it´s decided to evaluate most relevant situation, “the performance during normal operation”. For this, several sampling methods are proposed and ultimately a sampling is chosen in which a suitable lapse is selected for the day shift and another for the night shift. Thereby, the median and the average of the load of each day are plotted for the 24 hours, this way it´s shown that during 16:30 to 19:30 for the day shift and from 22:00 to 01:00 for the night shift, there is the lesser chance of occurrence for the operational breakdowns as shift change or collation. Before continuing with further analysis, the information obtained must be filtered from the influence of maintenance and failures downhill from the belt conveyor.The most adequate distribution is looked for the database obtained, but no good fit is achieved, therefor two parallel analyses are proposed, a specific one in which information will be segregated by relevant criteria in order to grasp a better understanding inside the data; and a general one in which performance can be read into as perceived by company.In the specific analysis, the data is segregated by operator´s groups, day and night shifts and administrative schedule, since an ANOVA proved that those were relevant factors, and due to some cases of multimodality 23 subsets are obtained, which were respectively transformed to normalize and standardize. Later on, a capability analysis is made for each one to evaluate the performance, for this a goal had to be set for the standard deviation.With this, is achieved an identification of which operator works best or worse in which instances and in which measure, knowing when attention is needed for the operators, coordination with dispatch, etc.For the general analysis it´s looked for the distribution with the lower Anderson-Darling index and the highest correlation coefficient, thereby attaining a distribution to associate the capability analysis.For the estimation of the benefit, an ideal case is proposed in which all failures are corrected achieving an increase in the ore delivery of 11.58%, this factor must be lowered so that it suits the impact of each alternative proposal.
Description
Catalogado desde la version PDF de la tesis.
Keywords
CALIDAD , MINERIA , OEE , SIX SIGMA , VARIABILIDAD