VICE Review Validated Baseline
with gap analysis
Mogalakwena Mine

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Improvement Opportunities Identified

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Skills Improvements

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Equipment Issues to Address

Key Findings Summary

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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.

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

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?

Business Inputs for Personnel

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.

Business Inputs for Equipment

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.

General Equipment Themes for Management Consideration

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.

Table: Detailed Don't worry, you did not miss out. See the next round of reviews in the below table.

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Table: Detailed comments and opportunities in personnel business inputs

BI Name	Expectation/Context	Related OFI	Workshop Discussion / OFI Detail	Who By/When
BMS-SMS-STD-103 Testing and Test Equipment	BMS-SMS-STD-103 Testing and Test Equipment	OFI:130 – Implement a program for more frequent servicing of field devices	Servicing of field devices – Develop a four weekly electrical service on field isolators to ensure the isolated function correctly. Particularly important environmental conditions. Purchase local isolator shrouds with rubber covers for those exposed to harsh environmental conditions.	Peter Charles / 1/6/23
Citect indication and process interlocking	Citect indication and process interlocking	OFI:114 – Review display logic in CITECT	Review display logic in CITECT – The Review team noted that CITECT does not correctly represent the belt press filter mimics when isolated. Belt press filter logic will maintain the last known values and requires masking with MCC isolators.	Peter Charles / 1/2/23
CoE Formal process for removing a personal lock	Formal process for removing a personal lock – that involves signed approval from a senior site leader after positive communication with lock owner.	OFI:128 – Establish black lock register	Establish black lock register – Review how the black locks deployed are communicated with task coordinators. The validation team discussed options use of handover document managed by task coordinators.	Joe Bridge / 30/11/22
Electrical and Mechanical Task List Developed	The permit development process is rigorous and tries to prevent any gaps in control of energy.	OFI:102 – Update MoC for Drawings	Update Change Management Form to consider new equipment and requirements to update drawings, P and IDs, isolation matrix, maintenance strategy (SAP)	Brad Connolly / 30/11/22
Electrical and Mechanical Task List Developed	The permit development process is rigorous and tries to prevent any gaps in control of energy.	OFI:103 – Audit Isolation Matrix	Audit Isolation Matrix – Establish an event in INX for the periodic review of the CHPP Isolation Matrix and the associated P and ID drawings	Brad Connolly / 16/12/22
Electrical and Mechanical Task List Reviewed	Electrical and Mechanical Task List Reviewed	OFI:104 – Update CoE – IM Audit	Update the CoE – IM Audit – Update the Control of energy standard to document the requirement for a 12 monthly review of the isolation matrix	Brad Connolly / 30/11/22
	The control of energy standard nominates a 12 monthly review of the CHPP isolation matrix	OFI:105 – Update CoE for CIP/IP	Update the Control of energy standard to include the Complex Isolation Process and Isolation Permit	Brad Connolly / 30/11/22
	The change management forms will discuss requirements/trigger for updating the isolation matrix	OFI:122 – Managers to assign Isolation matrix review	Managers to assign Isolation matrix review – The audit process should be assigned to a manager role who can then Delegate to a group of people. It is important that the task is not always the same person every year so that there is an independent review of the isolation points.	Brad Connolly / 16/12/22
Isolation Permit (Complete Process)	The updated Isolation Permit process will include guidance for Electrical and Mechanical Task List Development, Electrical and Mechanical Task List Review, Isolation Permit Development, Isolation Permit Approval, Workgroup Review, Workgroup Participation, and permit cancellation and system re-energisation.	OFI:113 – Aux Drive	Aux Drive – Review the current requirement to ‘inch’ the chain drive on feeder breakers during scheduled maintenance, with consideration to remove the requirement. Alternatively, enquire with McLanahan about an external auxiliary drive which allows the chain to be moved (inched) for maintenance purposes with the main drive isolated	Hugh Sellers / 30/11/22
		OFI:125 – Add discussion requirement to Permit Holder and Authorised Isolator training	Add discussion requirement to Permit Holder and Authorised Isolator training – Add an assessed element for permit holders to discuss the front page of the permit.	Brad Connolly / 30/11/22
		OFI:131 – Add competency element into the Restricted Electrical Workers Package	Add competency element into the Restricted Electrical Workers Package – Add in awareness slide regarding contractor, remote controlled drives in the CHPP.	Peter Charles / 31/12/22
		OFI:132 – Decide on auxiliary drive requirements	Decide on Auxiliary drive requirements – Review the current requirement to ‘inch’ the chain drive on feeder breakers during scheduled maintenance, with consideration to remove the requirement.	Hugh Sellers / 30/11/22