Leica Geosystems Jigsaw360 Dispatcher

Optimizer Training Module

Agenda and Objectives

Equipment Cycle Overview The Theory behind the Optimizer How the Optimizer work How to influence the Optimizer Summary

Equipment Cycle

Empty

Traveling Tipping

Waiting

Spotting Backing

Queued

Loading
Hauling

Truck Cycle Activities

Traveling
Traveling Empty to the Shovel Empty trucks automatically enter the traveling activity after ready or after departing from a dump more than departure radius of the tipping point

Waiting

Waiting at the Shovel

Starts when Truck stops in the loading area within the shovel waiting radius Starts when Truck starts backing at the shovel within spotting radius of shovel Starts after first dipper from VIMS/TPMS/PLM, or truck in reverse stops (speed = 0) within the shovel loading radius Starts when the Truck leaves the Shovel and traveled by more than shovel departure radius

Spotting

Spotting at a Shovel

Loading

Loading at the Shovel Hauling from the Shovel to a Dump area Queued at the Dump area Backing at Dump area Tipping at Dump area

Hauling

Queued Backing

Starts when truck stops within the Dump boundary Starts when truck backs at Dump area

Tipping

Starts after stopping after backing at Dump and VIMS/TPMS/PLM tipping detected

Shovel/Truck Cycle

Additional Activities
Out of Cycle Activities for Trucks
Inactive Any delay or down status

Empty

Truck is empty and ready waiting for an assignment

Loaded

Truck is loaded and ready waiting for an assignment

Moving Empty

Truck is traveling to a Shop or Shift Change location and is empty Truck is hauling to a destination that is not a dumping area

Moving Loaded

The Theory behind The Optimizer

Truck dispatch problem in open pit mining is dynamic and consists in answering the following question: Where should this truck go when it leaves this place?. The Dispatcher has to decide where is the best destination to send a truck in order to satisfy the production requirements (Alarie and Gamache, 2002)

Truck Dispatch problem can be solved using mathematical approach to find the optimal solution.
Optimizer is Jigsaw360 Module which do the automatic truck dispatching based on mathematical model.

The Theory behind Optimizer

Mine is really a series of location / node that are connected by roads or Path Optimizer maximise the production by allocated (assign) the trucks along the roads based on the capacity of the diggers.
Shovel A 3000 Tons/Hour
Dump 1

Shovel A 2000 Tons/Hour Dump 2

Segregated Circuits
1 min 14 min 9 min Capacity * Cycle Times = Number of Trucks (1 truck/4 min) * (14 + 1 + 9 + 4 )min= * 28 = 7 Trucks 1 min 19 min 15 min (1 truck/4 min) * (19 + 1 +15 +5)min= 1/5 * 40= 8 Trucks 5 min 4 min

Optimized Circuits
1 min 14 min

Capacity * Cycle Times = Number of Trucks

4 min 5 min

(1 truck/4 min) * (14 + 1 + 6 + 5 + 20 + 1 + 5 + 4 )min

6 min

* 56 = 14 Trucks

1 min 20 min 5 min

How the Optimizer work

Optimizer maximise production of the mine centrally on the server through assignments carried out on trucks in the pit. There are 2 Layer of Optimizer Calculation : Linear Programming (LP) Layer and Dynamic Programming (DP) or Assignment Layer LP layer output will produce an input for DP layer which then use by DP layer to make an truck assignment decision.

Inputs

LP

DP

Truck Assignment

How the Optimizer work : LP Layer

Shovel Capacity Constraints Haulage

Nodes Inputs Paths Linear Programming is the use of mathematical algorithms to maximise an outcome based on given inputs and known constraints. The Inputs are Nodes (Dump and Shovel) and The Paths (Roads) between the Nodes The Constraints are Shovel Capacity Constraints and Haulage Constraints

LP

Outcome

How the Optimizer work : LP Layer

Shovel Capacity Constraints is maximum shovel capacity in term of loading tonnes per hour inclusive of shovel spotting time. Shovel Capacity is calculated as:

Standard Truck Size (Standard Truck Size / Dig Rate) + (Shovel Spotting Time / 3600 )

Tons Hour

Standard Truck Size is the weighted average truck factor for the mine. Calculated as : Sum all Truck with its Capacity / Total Number Of Trucks Dig rate is The moving average load rate of the shovel over 4 loads

How the Optimizer work : LP Layer

Example calculation for Shovel Capacity

Standard Truck Size Shovel Digging Rate

Shovel Spotting time Shovel Capacity =

100 Tons 3400 Tons/Hour

20 Seconds = 2859,81 Tons/Hour

100 (100 / 3400) + (20 / 3600 )

How the Optimizer work : LP Layer

Haulage Constraints is the available truck along given paths inclusive of the locked trucks. The haulage constraint will not take into account the down trucks. Given the inputs, the known constraints and the object to maximise production, the Optimizer utilizes the LP Simplex algorithm to calculate and store the optimal tonnes per hour across each path, called the LP Rate. LP Rate is the optimal rate in tonnes per hour across each path between shovels and dumps and vice versa. This calculation is carried out based on real time inputs every 0.5 seconds.

Using LP Rate, the Optimizer calculate and stores Required Haulage for each path and each shovel within the mine.

How the Optimizer work : LP Layer

Shovel Capacity

Haulage

Nodes

LP
Paths

LP Rate

Required Haulage

Required Haulage is number of truck which required to achieve the optimal output and calculated as:
LP Rate x ( (truck cycle time to shovel ) + (z / 3600) ) where z is: (shovel spotting time + 3600) x (standard truck size / dig rate )

How the Optimizer work : LP Layer

Example calculation for Required Haulage

LP Rate or Feed Rate Standard Truck Size

Shovel Digging Rate Shovel Spotting time Truck Cycle Time

2580 Tons/Hour 100 Tons

3188 Tons/Hour 30 Seconds 600 Seconds

Z = (30 + 3600) x ( 100 / 3188 ) = 113,86 Required Haulage = 2580 x ( 600 + 113,86 ) = 511,60 Tons/Hour 3600 Number of Trucks required = 511,60 / Standard Truck size (100) = 5.12 Trucks

How the Optimizer work : DP Layer

Dynamic Programming Layer or Assignment Layer is the Part of Optimizer which produce truck assignments to optimize production within the Mine. Assignment Layer using the output of LP layer. Within the Assignment Layer, there are two type of truck assignments which made : 1. Truck to Shovel Assignments 2. Truck to Dump Assignments Truck to Shovel Assignment Inputs

LP

DP

Truck to Dump Assignment

How the Optimizer work : DP Layer

Truck to Shovel Assignments Truck to Shovel Assignments made when truck dumps it loads and therefore need a new shovel assignment. The following logic is used;
Find a neediest shovel Find a Free Truck Find Truck Lowest Assignment Cost

Find a Best Path

Not Locked to a shovel Greater Diff Delta Not Traveling Not Spotting Not Waiting Not Down Required haulage Actual Haulage

Priority
Queue Capacity

How the Optimizer work : DP Layer

Truck to Shovel Assignments The process to find the neediest shovel will be repeated. Restricted : By shovel, By Dumps, By Grades, By Queue Capacity and By Location
Find a neediest shovel

Find a Best Path

Find a Free Truck

Find Truck Lowest Assignment Cost

Find the next Lowest Cost

Restrict ed ? N

Repeat

Update Actual Haulage

Assign!

How the Optimizer work : LP Layer

Assignment Cost The optimizer continuously recomputed the next shovel assignment for each ready truck using the current truck positions and projected arrival times of trucks at shovel (ETA), then The algorithm computes a set of assignments, which minimize the total cost C. C = Ct * Ti + Ci * (Hi + Wi) Where : Ti Travel time of i'th truck assignment to a given LP path. Hi Projected shovel hang time at the time of truck arrival at shovel Wi Projected truck waiting time at the time of truck arrival at shovel Ct Relative cost for excess travel time, default 1.5 Ci Relative cost for idle time, default 1.0

How the Optimizer work : LP Layer

Assignment Cost This means, from formula, the trucks likely will assigned to the closer shovel Optimizer dynamic truck allocation aggressively minimizes truck and shovel idle times By using current truck position and ETA, Optimizer create ordered queue of trucks at each shovel.
Shovel A Projected Shovel Hang Time LP Path 1 Truck #1 to Shovel A Truck #2 to Shovel B Shovel B Truck Current Position

LP Path 2 Projected Truck Waiting Time

Dump

How the Optimizer work : DP Layer

Truck to Dumps Assignments Truck get their assignments to Dumps when they finished loading and start hauling The Logis is follows;
Trucks Enter Hauling State Dump Request for Given Material/Grade Y Dump Locks? N Y Assign! Find Dumps? N Loop all Dumps that are connected to the shovel truck loaded at Event no Active Paths

Assign!

Find Nearest Dump

How to Influence Optimizer

There are 2 ways to influence or control the optimizer: Influence the LP layer and Influence the DP (assignment) Layer. LP Layer : Adjust the Shovel Coverage DP Layer : Adjust the Priority, Change the Queue Capacity or Create Reassignment callpoint

How to Influence Optimizer : LP Layer

1. Percent Shovel Coverage Shovel Capacity x % Coverage = New Shovel Capacity

LP

LP Rate

Percent Shovel Coverage is parameter that can be used by Dispatcher to influence the output of LP Layer. Percent Shovel Coverage value is multiplied againts the calculated capacity before used as a constraints. For example, 3000 Tons/Hour Shovel with 50% coverage will only produce LP constraints = 3000 x 0.5 = 1500 tons/hour

How to Influence Optimizer : LP Layer

1. Percent Shovel Coverage Percent Shovel Coverage is useful to move the loads from Big Shovel to Small Shovel It would be possible in some scenarios for the larger capacity shovel with 100% coverage to consume all trucks in an under trucked mine. If we want to move material from some of the smaller shovels, we might reduce the coverage percentage on the larger shovel to allow some trucks to be assigned to the lower capacity shovel. Remember : Cutting down the big shovel coverage while the Shovel have high Capacity / Digging Rate, will reduce the shovel productivity, which may decrease the Mine productivity in general.

How to Influence Optimizer : DP Layer

2. Shovel Priority As mentioned briefly earlier, Shovel priority is taken into account when finding the next neediest shovel to assign a truck to. The values associated with the priorities are as follows: Low: 0.75 Normal: 1.0 High: 1.25

Shovel Priorities are multiplied against the Required Haulage before they are used in calculation between the Required Haulage from the LP Layer and the Actual Haulage

How to Influence Optimizer : DP Layer

2. Shovel Priority Required Haulage x Priority= New Required Haulage

New Required Haulage - Actual Haulage

Delta

Shovel Shovel A Shovel B Shovel C

Required Haulage 2580 2300 3188

Priority Low:0.75 Normal:1.0 High:1.25

Actual Haulage 1200 1500 1000

Delta 735 800 2985

Neediest Shovel

How to Influence Optimizer : DP Layer

3. Reassignment callpoint Sometime the Assignment that is made at the time tipping/dumping is not always the best assignment as the truck nears the shovel it is assigned to. Jigsaw has what called Reassignment callpoint to gets around this. Reassignment callpoint is the regular callpoint that configured as the Reassignment callpoint. Reassignment callpoint will: Look at all the shovels ahead of the reassignment callpoint Re-evaluate the current assignments when the truck enter the road segment to reassignment callpoint Using the same logic as Truck to Shovel Assignments above to determine the best shovel to go to.

How to Influence Optimizer : DP Layer

3. Reassignment callpoint Notice: Using too much reassignment callpoints will reduce the effectiveness of Optimizer and create an inefficiencies to the mine. Use only at key locations only.

Shovel A

DT001 Enter CP1->CP2 road segment Assignment change to Shovel B

Reassignment CP2 CP1 DT001 After tipping : Shovel A

Shovel B

Dump

How to Influence Optimizer : DP Layer

3. Reassignment callpoint

There is a reassignment cost involved, which is the cost that is calculated if the shovel is not the current assigned shovel. The system defaults the reassignment cost to: 240. Refer to Assignment Cost Formula, the extra cost will be add into the Assignment cost. C = Ct * Ti + Ci * (Hi + Wi) + 240

How to Influence Optimizer : DP Layer

4. Queue Capacities Shovel and dumps can have a queue capacity set for them. By using these capacities we can limit queuing at these locations. It is rare that this property has to be used, but in rare events, it can be used to limit truck assignments

Summary
In summary the Jigsaw 360 Optimizer is a complex system that utilises powerful Linear Programming algorithms to determine Required Haulage rates for mine paths connecting nodes. While it is complex, it is also simple in that the Dispatcher can only control / tweak four various input to adjust trucking assignments. The four inputs that can be adjusted to control assignments that have been outlined above, outside of restrictions, are; Percent Coverage Shovel Priority Reassignment Callpoints Queue Capacities Do not play too much with the inputs, in most case only Percent Coverage and Shovel Priority that need to be adjusted

Summary
To run the Optimizer effectively, you need to monitor the hanging and queuing of the shovels regularly as well as the LP vs Actual on the MTC. By using the above, we can ensure the Mine is running as optimally as possible and therefore production is maximised it is essential that the road network is maintained and callpoint elevations are correctly entered. This is important to accurately calculate the Travel time for free trucks being assigned. It allows the system to calculate accurate assignment costing.

Thank You!
Questions?