“Safety Risk Model

Trackless Mobile Mining Machinery Operation

for
South African

Open Pit/Cast Operations

An Industry wide perspective

Open Cast/Pit
MOSH
 Purpose
The model is a corner stone for the MOSH initiative’s process to identify
Leading Practices with the potential to make the biggest contribution to
industry wide Safety performance for trackless mobile mining machinery
operation
 Level One: Overall Model
Equipment
• Injury
Short term • Disability
• Body and organ vibration outcomes • Death
• Hand and feet injuries • Production loss
• All ranges of body injuries • Sec 54
• Sec52
Nature of
Operator Exposure

Outcomes
Nature of Exposures of the
the Hazard exposure
Information

Exposed
persons
Environment
• Machine Operators • Injury
• Maintenance Technicians
Long term • Disability
• Workers/Pedestrians outcomes • Death
Equipment • Lower ROI
• Increased
operation regulation
• Compensation
 Level two: Sources of Equipment Hazards
Level three:
Difficult/poor Causes of Equipment Hazards
access for
Difficult/poor
Persons working OEM
on Vehicle Nip point on
access for • Inadequate definition of use/poor understanding of
operators machines
use.

Poor Fatigue failure of • Inadequate field testing of equipment/components

Ergonomics/HF safety related • Inadequate risk analysis for specific requirements
of Machines components
• OEM design process inadequate
• Inadequate user field feedback
Inadequate Inadequate systems
provision Safety
For Equipment Systems • Lack of safety engineering competence
Visibility Design • Inadequate operability and maintainability analysis
Poor •Poor/no Human factors engineering
reliability of
•Inadequate design specifications
Safety
Equipment Systems Company
failure
Poor provision •Lack of user acceptance testing of
of new equipment designs
Machine Poor Safety Systems
fires Maintainability/ by OEMs • Inadequate user requirements specifications
maintenance
access
 • Machine Vibration
• Lack of sleep Level two: Sources of Operator Hazards
• Shift patters • Poor understanding
• Distance from work • Inappropriate PPE
• Repetitive work
of importance of training • Ineffective PPE Level three:
• Inexperience with training Not using / • Poor safety culture
• Poor discipline wrt medical design
Causes of Operator Hazards
• Substance abuse
wrong use • Double standards
• Cost of effective training of PPE
• Social conditions programmes • Familiarity • Poor selection criteria
• Poor physical condition • Difficulty to measure •Poor safety culture (Ergonomic review)
• Poor mental condition training effectiveness • Historic selection
Operator • New model machines
complacency Man /
Inadequate old operators
Operator Machine
• Overly elaborate training
Fatigue misfit
check list
• Checklist/Literacy level mismatch
• Checklist not risk based Inadequate • Poor understanding
• Production pressure competency of importance
Pre use • Inexperience with design
• Complacency Operator assessment –no
inspection of competence assessment
•No review of checklists emergency
simulation • Challenges to measure
• Risk to simulate
• High risk tolerance • Cost to simulate
• Cultural Poor Safety
• National Culture Bridging safety
• Social Dangerous devices
• Nuisance alarms
• Lack of understanding Operating • Poor reliability
of machine Poor fitness
cause & effect Poor Literacy/ •Poor safety culture
For work
risk • Sabotage
comprehension • Inadequate driver training
• Poor eye sight • perceived production
and experience
• Old drivers • Physically unfit impact
•Production pressure
• No test of risk • Medication impact
• Poor risk comprehension
Comprehension • Poor Health
• Over confidence/familiarity
• Lack of emergency experience
• Poor Safety Culture
 Level two: Sources of Equipment Operation Hazards
Level three: • Inadequate understanding of
• Inadequate understanding fully functioning equipment
of leading practices in traffic management
Causes of Equipment
and safety relationship
• Traffic management not fundamental Operation Hazards
mine design focus Poor
• Poor safety culture Inadequate equipment • Non systemic approach
• Inadequate understanding traffic health to mine design changes
management Inadequate
of full functioning equipment standards • Safety impact assessments not
mine
and safety relationship Lack of always done
design/layout/
• Capital cost constraints maintenance • Temporary vs Permanent
mine capacity
infrastructure • Production only considerations
changes

• Inadequate
Safety controls
Equipment too low on
awareness of new
• Operating procedures Sub-standard and and leading practices
evolved over many years
operation hierarchy of
unpractical • Poor continuous
• No physical verification of controls
operating improvement process
operating procedures procedures • Capital constraints
• Office based procedure review • Reviews after
• Composition of review teams incidents inadequate
Mismatch of operating
procedures and mine
Poor roads- design. • Poor management of mine
surface and design changes
Roads-surface
• Poor safety culture from gradient Insufficient • New operating procedures not
and gradient
management maintenance Recovery considered and/or not
standards are
• Road surface maintenance Standards and practically verified before
inadequate
not considered as critical for equipment issuing
safety • Copy and paste of procedures
• Standards not established for
specific environmental conditions
• Standards not established for
specific equipment characteristics
Level two: Sources of Information Hazards
Level three:
Inadequate/no Causes of Information Hazards
operator Poor spotter
communication signals
systems
.
• Information or the
lack thereof is not
generally viewed as a
source of hazards
Lack of/late
• Risk of no/poor
ground
stability
Information Failure of GPS information not
systems formally assessed
information

Lack off/late
incident Late/incomplete
information roads-surface and
gradient condition
information
Level two: Sources of Environmental Hazards
Level three:
Sudden Fall of Causes of Environmental
Flooding Ground
Hazards
Lightning

Dust
Environment

Rain