MANPOWER PLANNING OF AN IRON ORE MINES AND ORE PROCESSING PLANT– A CASE STUDY

PRESENTED BY: ANIRBAN DASGUPTA 2013MT0079 M.Tech (IEM) DMS, ISM DHANBAD

College Guide: Krishnendu Shaw Asst. Professor DMS, ISM Dhanbad

External Guide: D.S. Rekhi GM-IE&M HR&ES,JSPL Raigarh

Introduction

1DMS, ISM DHANBAD

Mining industry contributes 2 to 2.5% of total GDP of nation which is 10 to 11% of GDP of industrial sectors.

India possesses the 7th largest reserves of iron ore in the world

Demand of Ore increased

Production of Steel is increased

Manpower planning of Mines and Ore Processing Plant is essential

PROJECT GENESIS

Production need to increase proportionally with demand

of Iron Ore.

To support the required production, manpower

planning of Iron Ore Mines and Ore Processing Plant

(OPP) is required on urgent basis.

2DMS, ISM DHANBAD

Objective

To study and analyze the existing Manpower.

Propose the manpower requirement.

Optimize and make a model for manpower requirement .

3DMS, ISM DHANBAD

Literature Review

4DMS, ISM DHANBAD

Bowey (1977) defines:

Strategy for matching future manpower numbers and skills with organizational activities

Lagodimos and Leopoulos (2000) Proposed:

A mixed integer programming based model for the manpower shift-planning problem

L.H.C. Tippett(1935 ) Develops:

Work sampling (WS) technique, consists of a chain of random sampling (or observations) of the activities being carried out by the group of workers (or possibly the machines) under study

Case Study of Existing System

5DMS, ISM DHANBAD

Mining process and Production

• HEMM’s are used (e.g. Dozer, Shovel)

• Production of Mines 2.5 MTPA

Manpower

• In Mining 53 comp. and 47 contract employee

• In OPP 23 company and 60 contractual employee

Material Handling

• HEMM’s are used for material handling

Layout of OPPAF: Apron FeederDB: Down BeltSC: ScreenSD: Single DeckPC :Primary CrusherUB: Up BeltFB: Fines BeltCC: Cone CrusherDD: Double DeckRB: Recirculation BeltLC: Long ConveyorFEB: Feeder BeltJB: Junction BeltMP: Mini Plant

Ore Processing Plant Layout

Tipper Dumper

Feed Hopper

ROM (0-800mm)

AF

0-20mm (20MT/Hr) AF DB

0-25mm (250MT/Hr) SC 1 DB

SC 1 (SD)

Over Size

Primary Jaw Crusher (250TPH)

PC DB 0-100mm (100MT/Hr)

SC 2 (SD)

SC 2 DB

0-25mm (30MT/Hr)

SC 3 UB 0-25mm (250MT/Hr)

SC 3 (SD)

FB 3

0-3mm (300MT/Hr)

Fines Hopper

Tipper Dumper

CC UB Seconday

Cone Crusher

25-100mm (100MT/Hr)

CC DB 0-30mm

SC 5 (DD) SC 4 (DD)

LC 2

5-25mm (50MT/Hr)

Capacity 1500 MT Bin Hopper

FEB 5

FEB 4 0-6mm (50MT/Hr)

FB 1

0-6mm (50MT/Hr)

SC 3 DB 0-25mm (200MT/Hr)

0-20mm (150MT/Hr)

JB SC 6 (SD)

0-6mm (50MT/Hr) SC 6 DB

Fines Stock LC 3

0-20mm (130MT/Hr)

MP Hopper

MP Feed Belt

0-20mm (130MT/Hr)

MP SC

Recovery Belt (100MT/Hr)

Product (5-20mm)

Product (5-25mm)

Material Flow Belt/Conveyor

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Methodology

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Present Production level and related Production Equipment

Nature of Job (Work-content assessment using Work Sampling Technique)Volume based, Supervision based, Position based

Skill and Qualification Required

Statutory/Non-statutory Requirement

Technical/Non-Technical Requirement

Work sampling

Work sampling is defined as the application of statistical sampling techniques to the study of work activities. In the audit context, work sampling is typically used to estimate the proportion of workers' time that is devoted to different elements of work activity. Work sampling is also known as activity sampling. It can be also used to estimate equipment or vehicle utilization

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Work sampling

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Frequency of Study:

Samplings are made randomly or at fixed intervals.

Study Length:

Depends upon the job type. It is very important to make sure that equal numbers of sub-cycles are included in the study

Establish independent workload:

This will help insure that as many of the underlying variables which govern the work performed will be accounted for.

Working continuously without any break is not possible for any worker. Even under the best working method situation, the job will still demand the expenditure of the human effort and some allowance must therefore be made for recovery from fatigue and for relaxation. Allowances must also be made to enable the worker to attend to his personal needs.

Allowances

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1. Rest and personal allowance: Drinking water, Taking rest

2. Process allowance: Waiting for work, Waiting for material

3. Contingency allowance: Waiting for the inspector, Consulting the supervisor

4. Special allowance: Calibration, Maintenance, Shut down

5. Policy allowance: According to the organizational policy

Types of Allowances

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Standard Time & Normal Time

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• Standard Time: Time required by an average skilled operator, working at a normal pace, to perform a specified task using a prescribed method

𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑡𝑖𝑚𝑒=𝑁𝑜𝑟𝑚𝑎𝑙𝑇𝑖𝑚𝑒+ 𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 .

• Normal Time: A standard performance time with 100% rating is considered as Normal Time to perform a job

𝑁𝑜𝑟𝑚𝑎𝑙𝑇𝑖𝑚𝑒=𝑂𝑏𝑠𝑒𝑟𝑣𝑒𝑑𝑇𝑖𝑚𝑒∗(𝑂𝑝𝑒𝑟𝑎𝑡𝑜𝑟 𝑅𝑎𝑡𝑖𝑛𝑔÷ 𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑𝑟𝑎𝑡𝑖𝑛𝑔)

Manpower Planning Process

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• Secondary data was collected from departments logbook, register etc.

Data Collection

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• Work Sampling technique is used for the field study of existing system.

Existing Deployment

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Mines

Total Employees: 100

Company Employees: 45Contractual Employees: 55

Ore Processing Plant

Total Employees: 83

Company Employees: 23Contractual Employees: 60

Nature of job

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Job

Volume Based

Position Based

Supervision Based

• Volume based manpower in Mines is Distributed in different HEMMs, their assessment is done depending upon the vehicle requirement in next section.

• Manpower (OPP): 5 Company, 27 Contractual• To determine Manpower required for different

activates in OPP following Mathematical formula is used:

Volume Base manpower

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• Requirement of the position in overall operation is evaluated

• HEMM’s: 4 Shovels, 1 Drilling Machine, 8 Tippers, 1 Grader, 1 Dozer

• HMV’s and LMV’s: 1 water tank, 1 diesel tanker, 1 explosive van, 6 LMV and 2 Ambulance

• Manpower (Mines): 70

Position based manpower (Mines)

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• Assessment of vehicle requirement is done by using following formula:

• To determine Manpower required for different activates in Mining following Mathematical formula is used:

• A excel model is prepared:Mining Model.xlsx

Vehicle Requirement Analysis

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-1

1

3

5

7

9

11

13

15

17

19

21

23

25

27

8

4

1 1 1 1 1

5

3

1

25

16

3 2 2 2

67 7

Nos. of Vehicle Nos. of Manpower

Vehicle Vs. Manpower

Manpower assessment for Position Based JobDescription Measure

JE /Foreman 4 Nos.

Feed Hopper 3 Nos.

Primary Crusher, Screen-2, Down Belt 3 Nos.

Cone Crusher (Secondary Crusher) & SC-3 4 Nos.

Screen-4 & Screen-5 6 Nos.

Fines Hopper 4 Nos.

Bin Hopper 3 Nos.

MP Hopper, Screen-6 6 Nos.

Mobile Screen Plant 7 Nos.

EOT Crane Operator1 Nos.

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Position based manpower (OPP)

• Position based manpower of OPP is decided on the basis of positions required for Operation. Following table show the different requirement.

• This type of manpower depends upon the number of area need to supervise or number of men need to supervise.

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Supervision based manpower

Company (E) Contract (E) Company (P) Contract (P)0

5

10

15

20

25

30

35

40

45

37 3735

41

16

10

35

0

Manpower mapping based on Nature of Job for Mines

Positional ManpowerSupervision manpowerVolume based Manpower

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Manpower (Mines)

Company (E) Contract (E) Company (P) Contract (P)0

5

10

15

20

25

30

35

12

33

12

29

6

0

5

0

5

27

1

21

Manpower assessment based on Nature of Job in OPP

Positional ManpowerSupervision manpowerVolume based Manpower

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Manpower (OPP)

Manpower assessment based on Qualification of Mines

QualificationExisting Company Manpower Proposed Company Manpower

Company Contract Company Contract

B Tech 0 0 0 0

Diploma 0 0 0 0

Graduate 2 5 1 3

ITI 0 0 0 0

Skilled 31 19 30 23

Unskilled 0 0 0 0

Semi-Skilled 6 16 6 15

Foreman Certification 3 1 8 0

Mining Mate certification3 6 16 0

Ist Class Certificate 5 0 5 0

2nd Class Certificate 3 0 4 0

Total 53 47 70 41

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Skill and Qualification Required

Manpower mapping based on Qualification of OPP

QualificationExisting Company Manpower Proposed Company Manpower

Company Contract Company Contract

B. Tech 1 0 1 0

Diploma9 0 8 0

Graduate0 1 0 1

ITI 8 33 7 31

Skilled2 11 2 9

Unskilled3 15 0 9

Total 23 60 18 50

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Skill and Qualification Required

Manpower mapping based on Statutory Requirement of Mines

Statutory/ Non-Statutory

Existing Proposed

Company Contract Company Contract

Statutory 14 7 33 0

Non-Statutory 39 40 37 41

Total 53 47 70 41

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Statutory/Non-statutory Requirement

Manpower mapping based on Statutory Requirement of OPP

Statutory/ Non-StatutoryExisting Proposed

Company Contract Company Contract

Statutory 0 0 0 0 Non-Statutory 23 60 18 50 Total 23 60 18 50

Manpower assessment based on Technical Requirement of Mines

Technical/ Non-technicalExisting Proposed

Company Contract Company Contract

Technical 15 7 34 0

Non-Technical 38 40 36 41

Total 53 47 70 41

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Technical/Non-Technical Requirement

Manpower mapping based on Technical Requirement of OPP

Technical/ Non-technicalExisting Proposed

Company Contract Company Contract

Technical 20 46 18 40

Non-Technical 3 14 0 10

Total 23 60 18 50

• As per our assessment, there were total 4 extra men required including Mines and OPP. Result shown bellow.

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Conclusion

Mining Manpower

OPP Manpower

Total manpower deployed

0 20 40 60 80 100 120 140 160 180 200

100

83

183

111

68

179

Proposed

Existing

Thank You