COST CONTROL MANAGEMENT

Presented By
Tri Okta Maulana
BACK GROUND
PROFIT ($)

REVENUE COST

PRODUCTIO
OWNING COST
N

OPERATING COST
COST
COST

OWNING COST OPERATING COST

DEPRECIATION FUEL

LUBE , GREASE,
INTEREST FILTER

MAINTENANCE &
INSURANCE TYRE

TAXES OPERATOR WAGES

PRODUCTION COST CONTROLLING
 PRODUCTION CONTROL PROCESS CONCEPT

GROSS PROFIT
( GP )

REVENUE PRODUCTION COST

UNIT PRICE

PRODUCTION

PRODUCTION SECTION

Employee Compensation

Repair & Maintenance

PRODUCTIVITY WORKING HOURS Cost

PLANT SECTION Consumables Cost

STANDBY HOURS
Subcontractor Cost
AVAILABLE HOURS
Depreciation Cost
S1 : Rain/Smog/Fog
Machine Capacity S2 : Slippery
S3 : Flood
S4 : Dust MOHH MAINTENANCE HOURS
Material Condition S5 : Rest & Meal
S6 : Daily Shift Change
S7 : Weekly Over Shift
S8 : Holiday
Work Condition S9 : No Operator
S10 : Operator Absence Breakdown CODE : B/D Compartment :
S11 : No Loader/Hauler/Prime mover/Vessel/Dozer
Work Method S12 : Hopper/Crusher Shutdown B1 : Waiting Part C1 : Engine & Acc.
S13 : Stoppage B2 : Waiting Mechanic C2 : Transmission & TC
S14 : Front/Road/Disposal Maintenance B3 : On Process C3 : Diff & Final Drive
Operator Condition S15 : Wait for Blasting B4 : External Service C4 : U/C & Tire
(Skill & Attitude) S16 : P5M/Safety Talk/Pre Use Check B5 : Accident C5 : Hydraulic System
S17 : Production Re-Scheduling B6 : Others C6 : Electrical System
S18 : Pit/Front/Disposal Movement C7 : Pneumatic System
Effective Supervision
S19 : No Area C8 : Braking System
S20 : No Order/No material (Ob & Coal) C9 : General ( Attc etc.)
5
PRODUCTION COST
PRODUCTION COST IS COST WHICH EXPEND TO EXCAVATE 1 BCM/TON
OF WASTE/COAL

PRODUCTION COST

LOADING COST HAULING COST SUPPORT COST

DOZING COST

ROAD MAINTENANCE
COST
WATER TRUCK
COST
LIGHTING COST
HOW TO CONTROLLING
BUDGET COST MORE THAN ACTUAL COST

OpsCost Prodty EffWH Prod TotalCost Remarks

$/Hr Qty BCM/Hr Hr BCM $ $/BCM

PC1250 114.60 1 400 8 3200 917 0.29 -->LoadingCost
777A 109.43 5 80 8 4,377 1.37 -->HaulingCost
D8R 97.00 1 8 776 0.24 -->SupportCost
D85SS 51.00 1 8 408 0.13 -->SupportCost
14H 45.99 1 8 368 0.11 -->RoadMaintenanceCost
WT 9.06 1 4 36 0.01 -->RoadMaintenanceCost

WASTEREMOVALCOST($/BCM) 2.15
HOW GET BUDGET COST
BUDGET COST $/BCM

PRODUCTION MORE COST LESS

PRODUCTIVITY DEPRE RATE

WH EXTERNAL HIRE

FUEL CONSUMPTION

PRODUCTION
 AFFECTING FACTORS TO DETERMINE HOURLY PRODUCTION OF MACHINE CALCULATION

Productivity

Machine Material Work Work Operators Effective

Capacity Condition Condition Method Condition Supervision

Material Front Area Loading Skill /

Material
Swelling Fragmentation Condition Method Knowledge
Skill
Material Haul Road Dozing
Cohesive
Attitude
Condition Method
Material Crushing Plant Other Attitude
Weight
Leadership
Condition Method

Attachment
Attachment Conversion Correction Job Efficiency
Specification Factor Factor Factor

9
 MANAGEMENT FLEET
1. LOADING POINT
Parameter
1. Width
2. Drainage
3. Bench Height
4. Swing Angle

WIDTH
RULE : 1. Loading tool move without obstacle
2. Truck maneuver by one times turning

DRAINAGE
RULE : No Water trapped at Loading Floor

BENCH HEIGHT
RULE : Bench Height = Truck Height = Stick Length

SWING ANGLE
RULE : Swing angle 400 600
 MANAGEMENT FLEET
I. Loading Point Management
Goal :
To prepare/provide proper condition to support excavator/truck operate in safe (man
and machine) and productive
Drive By

Through Gate

Box Cut

Over the Rail

MANAGEMENT FLEET

Jarak truck terlalu jauh

Lantai Loading susah dijangkau bucket (Potensi
terperosok)
Banyak ceceran dan lantai loading
bergelombang
Loading time lama
Bucket fill factor maximum
Swing Loaded Time singkat
Digging sambil membentuk lantai
kerja (flat)

Bucket Fill Factor Rendah

Jumlah Pass banyak
Digging Time Lama
Swing Loaded Time lama
 MANAGEMENT FLEET
2. HAUL ROAD
Parameter
1. Road Width
2. Grade
3. Road Surface/Rolling Resistance
4. Drainage
5. Superelevation
6. Sight Distance VS Stopping Distance

WIDTH
RULE : Road width must be wide and safe enough for pass
RADE
ULE : Design Mine road with slightly and consistent grade, More slight more good

DRAINAGE/CROSS FALL
RULE : Design cross fall grade as minimum as possible
No Water Trap on Road Surface

URFACE/ROLLING RESISTANCE
ULE : No tyre trace found on road surface (almost no tyre penetration)

UPERELEVATION
ULE : If we need trucks on maximum speed over the curve, we have to slope the curve

SIGHT DISTANCE VS STOPPING DISTANCE

RULE : Sight Distance must be greater than Stopping Distance
 MANAGEMENT FLEET
II. Haul Road Management
Goal :
1. To prepare/provide good haul road condition to allow trucks travel in optimum
speed with safe and comfort (to operator and machine)
2. To minimize time on road maintenance work
 MANAGEMENT FLEET
ta
ling cost bisa mencapai 50% dari total cost waste removal (Open Pit)

Budget
ACPNow $/BCM %
Kerusakan Komponen Truck Design &
Kerusakan Ban Maintenance
LoadingCost 0.28 14% Konsumsi Fuel
Haul Road
Hauling Cost 1.08 56% Accident
RoadMaintenanceCost 0.13 7%
SupportCost 0.45 23%
WasteRemovalCost 1.94 100%

Pertimbangan dalam mendesign & memaintain

Haul Road
Truck Road

Weights Designed Grade

Rimpull Performance Consistent Grade
Retarding Performance Rolling Resistance
Surface conditions
Traffic Layout
 MANAGEMENT FLEET
3. DUMPING POINT

Parameter Parameter
1. Berm Height 1. Tanggul Dumpingan
2. Accessibility 2. Akses Dumpingan
3. Traffic 3. Lalu lintas Dumpingan
4. Drainage 4. Drainage Dumpingan

BERM
RULE : Safety berm Height = wheel height, Base Width = Berm Height
WARN : DO NOT ALLOW TRUCK STOPPED BY BERM

ACCESS
RULE : Allow the truck enter and exit dump area without slowing down

TRAFFIC/WIDTH
RULE : Enough space at dump area for truck to maneuver before dump and space for Dozer

DRAINAGE
RULE : If we need trucks on maximum speed over the curve, we have to slope the curve
 MANAGEMENT FLEET
III. Dump Management
Goal :
1. To prepare/provide dump area in standard condition
2. To manage equipment on dump area
BE MORE PRODUCTIVE WITH LOW COST
THANKS
OWNING COST
DEPRECIATION

CRAWLER TYPE

DELIVERED PRICE RESALE VALUE

DEPRECIATION = -------------------------------------------------
DEPRECIATION PERIOD IN HOURS

TYRE TYPE
DELIVERED PRICE RESALE VALUE TYRE
PRICE
DEPRECIATION =
----------------------------------------------------------------
DEPRECIATION PERIOD IN HOURS
INTEREST INSURANCE - TAXES

FACTOR x DELIVERED PRICE x ANNUAL

RATES
DEPRECIATION = --------------------------------------------------------------
ANNUAL USE IN HOURS
(n1)(1
r) n : Life time of Equipment in
FACTOR = 1 - Years
---------------------- r : Resale Value in %
2n
OPERATING COST
CRAWLER TYPE

HOURLY FUEL COST = HOURLY FUEL CONSUMPTION X LOCAL UNIT PRICE OF FUEL

HOURLY LUBRICANT COST = HOURLY LUBRICANT CONSUMPTION X LOCAL UNIT PRICE OF

LUBRICANT

HOURLY FILTER COST = 0.50 X TOTAL OF HOURLY LUBRICANT COST

HOURLY R/M COST = BASIC REPAIR COST X EXTENDED MULTIPLIER

TYRE TYPE

HOURLY FUEL COST = HOURLY FUEL CONSUMPTION X LOCAL UNIT PRICE OF FUEL

HOURLY LUBRICANT COST = HOURLY LUBRICANT CONSUMPTION X LOCAL UNIT PRICE OF

LUBRICANT

HOURLY FILTER COST = 0.50 X TOTAL OF HOURLY LUBRICANT COST

HOURLY R/M COST = BASIC REPAIR COST X EXTENDED MULTIPLIER

HOURLY TYRE COST = TYRE PRICE / ESTIMATED TYRE LIFE (HOUR)

 MANAGEMENT FLEET
Road Design
Proper Width

One-way (straights/corners)

Two-way (straight)

Two-way (corner)

Minimum Safe Road Widths for Cat Mining Trucks

Truck Width (m) One way Straight & Corner 2 Way Straight 2 Way Corner
777A 5 15 17.5 20
MANAGEMENT FLEET
Road Design
Grade

8%
4m
Grade Resistance = [y (meter)/x (meter)] * 100%

50 m
MANAGEMENT FLEET
Road Design
Superelevation
Speed of Vehicle (km/hr)
Turn Radius
15 20 25 30 35 40 45 50 55
25m 7% 13% 20%

50m 4% 6% 10% 14% 20%

75m 2% 4% 7% 10% 13% 17% 22%

100m 2% 3% 5% 7% 10% 13% 16% 20%

125m 1% 3% 4% 6% 8% 10% 13% 16% 19%

150m 1% 2% 3% 5% 7% 9% 11% 13% 16%
175m 1% 2% 3% 4% 6% 7% 9% 11% 14%
200m 1% 2% 3% 4% 5% 6% 8% 10% 12%
300m 1% 1% 2% 2% 3% 4% 5% 7% 8%
400m 0% 1% 1% 2% 2% 3% 4% 5% 6%
500m 0% 1% 1%
10%
1% 2% 3% 3% 4% 5%
10m

100m
MANAGEMENT FLEET
Road Design
Rolling Resistance

tyre penetration

Hard, well-maintained road 1.5% (practical minimum)

Well-maintained road with flex 3%
25 mm/1 tyre penetration 4%
50 mm/2 tyre penetration 5%
100 mm/4 tyre penetration 8%
200 mm/8 tyre penetration 14%
RR = 2 % + 0.6 % per cm tire
penetration
Road Design
Drainage System

Crossfall Road Crossfall

Shoulder
% 1% - 4 Shoulder
1% - 4 %

Drain Drain

Road Base

Maximum cross fall grade = 4%

Increasing slope = increasing potential for uneven tire/bearing wear

1% to 2% Well drained, well compacted running surface

with longitudinal grade greater than 3%
2% to 3% Normal haul road with average drainage and surface
compaction. Longitudinal grade less than 3%
3% to 4% Inclines, poorly drained haul roads with poorly
compacted running no matter what longitudinal grade
 MANAGEMENT FLEET
Road Design
Sight Distance (Visibility)

Vertical Alignment

Horizontal Alignment
 MANAGEMENT FLEET
Road Design
Total Resistance

Grade Resistance = (5/50)*100% = 10%

Rolling Resistance = 2%+(0.6% x 5)
= 2%+3% = 5%
otal Resistance = 10% + 5%
= 15%

10%

5 meter
5 cm

50 meter
 MANAGEMENT FLEET
Road Design
Total Resistance VS Machine
 MANAGEMENT FLEET
Trucks
Dump enter
Designat high speed, parallel to edge.
Trucks
- brake in straight line, then turn and stop
to
reverse to dump.

Floor is
smooth

Safety berm Height = wheel height

Base Width = Berm Height
MANAGEMENT FLEET