B.P., L.P. & D.P.: Understanding The Algorithms
B.P., L.P. & D.P.: Understanding The Algorithms
FLEET OPTIMIZATION
Copyright ©2008 Modular Mining Systems, Inc. All rights reserved.
LEGAL NOTICE: The contents of these materials are protected by federal and international
intellectual property laws. No portion of these materials may be reprinted, republished, modified,
reproduced, sold or distributed in any form without the express written consent of Modular
Mining Systems, Inc. These materials may contain third party copyright and/or trademark
materials, the use of which may not always have been specifically authorized by the intellectual
property owner. All copyrights and/or trademarks contained in these materials are the sole and
exclusive property of their respective owners.
These materials, including third party information, are provided for information purposes only.
Actual specifications may vary from those documented in these materials. Consult your local
Modular Mining office for further details.
2
D.1.1.1.00.A – Title: Understanding the Algorithms. “Fleet Optimization”
Objectives
At the conclusion to this session the learner will be able to:
• 00.1 Explain the Haulage Cycle and calculate Flow Rate.
3
Spot Time = 1 Min
THE HAUL CYCLE
Load Time = 2 Min
Dump Time = 2 Min
Full Haul
Load 11 min
Spot Dump
8 min
Queue Empty Haul
8 min
Queue Empty Haul
Spot Dump
8 min
Queue Empty Haul
Full Haul
Load 11 min
Spot Dump
8 min
Queue Empty Haul
Spot Dump
8 min
Queue Empty Haul
3
Truck 3 ARRIVES and spots
Spot
under the loading unit.
Dump
NEXT ACTION : FIRST BUCKET
8 min
Queue Empty Haul
Spot
NEXT ACTION : WAIT FOR
SHOVEL Dump
8 min
Queue Empty Haul
Full Haul
Load 11 min
Truck 2 GO to DUMP. 3 min
into full haul
Dump
NEXT ACTION : ARRIVE
Spot
8 min
Queue Truck 4 ARRIVES and spots Empty Haul
under the loading unit.
Full Haul
Load 11 min
Truck 2 GO to DUMP. 4 min
Truck 3 GO to DUMP. 1 min into full haul
into full haul
NEXT ACTION : ARRIVE
4 NEXT ACTION : ARRIVE
8 min
Queue Empty Haul
Spot Dump
8 min
Queue Truck 5 ARRIVES and spots Empty Haul
under the loading unit.
Full Haul
Load 11 min Truck 2 GO to DUMP. 7 min
Truck 3 GO to DUMP. 4 min into full haul
into full haul
NEXT ACTION : ARRIVE
NEXT ACTION : ARRIVE
Spot
Truck 5 FIRST BUCKETS
under the loading unit. Dump
NEXT ACTION : WAIT FOR
SHOVEL
8 min
Queue Empty Haul
Spot Dump
Truck 1 ARRIVE. 15min
into cycle. 1 min into
8 min dump time
Queue Truck 6 ARRIVES and spots Empty Haul NEXT ACTION : ASSIGN
Spot
Truck 6 FIRST BUCKETS
under the loading unit. Dump
NEXT ACTION : WAIT FOR
SHOVEL
8 min
Queue Empty Haul Truck 1 ASSIGNS. 16min
into cycle. 0 min into
empty haul
Spot 1 Dump
Truck 2 ARRIVE. 18min
into cycle. 1 min into
8 min dump time
Queue Truck 7 ARRIVES and spots Empty Haul NEXT ACTION : ASSIGN
under the loading unit.
Spot
Truck 7 FIRST BUCKETS
under the loading unit. Dump
1
NEXT ACTION : WAIT FOR
SHOVEL
8 min
Queue Empty Haul Truck 2 ASSIGNS. 19min
into cycle. 0 min into
empty haul
Spot 2 Dump
1 Truck 3 ARRIVE. 21 min
into cycle. 1 min into
8 min dump time
Queue Truck 8 ARRIVES and spots Empty Haul NEXT ACTION : ASSIGN
under the loading unit.
Spot 1 2
Dump
Truck 8 FIRST BUCKETS
under the loading unit.
8 min
Queue
NEXT ACTION : WAIT FOR Empty Haul Truck 3 ASSIGNS. 22min
into cycle. 0 min into
SHOVEL empty haul
Spot 3 Dump
2 Truck 4 ARRIVE. 24 min
into cycle. 1 min into
8 min dump time
Queue Truck 1 ARRIVES and spots Empty Haul NEXT ACTION : ASSIGN
under the loading unit.
SHOVEL TRUCK
HANG QUEUE
TRUCK SHOVEL
QUEUE HANG
0 Mins 0 Mins
TIME TIME
UNDERTRUCKED OVERTRUCKED
Achieving a 0 minute truck queue Achieving a 0 minute shovel hang
(Average per truck per cycle), can (Average per truck per cycle), can
produce unwanted hang time on the produce unwanted queue time on the
loading unit. haulage units.
SHOVEL TRUCK
HANG QUEUE
0 Mins
TIME
BALANCED CYCLE
A balanced cycle achieves the minimum shovel hang and the minimum truck queue time
(average per truck per cycle), that is possible during any individual shift, given the various
mine constraints present during that shift.
Empty Haul
Full Haul
Load &
Spot Dump
Queue
Full Haul
Dump
HaulRoute® as a real-time
Load &
graphical representation of Spot
26
Purpose of DISPATCH
DISPATCH® AS A REAL-TIME PROBLEM SOLVER
®
• B.P Model
• L.P Model
• D.P Model
27
B.P, L.P & D.P
BEST PATH
The first model in the DISPATCH® systems 3 model optimization strategy is B.P. or Best
Path. This is the determination of the best available path between two points and
works on shortest distance as the criteria.
It uses the MineGraphics™ scale representation of the pit as the basis for its
calculations of paths. This is why the accuracy of the mine model must always be
maintained. This is what is meant by the term “healthy road network”.
The mine is a dynamic environment where roads and ramps are changing on a shift by
shift basis. The dispatcher should be monitoring and updating the locations and road
network on a regular basis throughout their shift.
28
B.P, L.P & D.P
BEST PATH
DUMP 2
DIGGER 1
CP2 DIGGER 3
CP3
CP1
DUMP 1
DIGGER 2 DUMP 3
29
B.P, L.P & D.P
BEST PATH
DUMP 2
DIGGER 1
CP2 DIGGER 3
CP3
CP1
Closed Road
DUMP 1
DIGGER 2 DUMP 3
30
B.P, L.P & D.P
LINEAR PROGRAMMING B.P. OPTIONS
31
B.P, L.P & D.P
32
B.P, L.P & D.P
LINEAR PROGRAMMING
L.P. depends on up-to-date cycle time information. It is important to update L.P.
when changing shovel dig rates. L.P. will automatically recalculate when road
network changes are made or every 30 minutes.
33
B.P, L.P & D.P
LINEAR PROGRAMMING
L.P. is able to match larger trucks with larger loading units Shovels
have different digging rates based on truck size which L.P. uses to
make the best match between loading and haulage units.
34
B.P, L.P & D.P
LINEAR PROGRAMMING
Simplify the L.P. solution by downing/standby unused dumps.
Maximizes overall truck productivity subject to:
• Blending constraints.
35
L.P. Global Parameters
1
36
L.P. Global Parameters
2
37
L.P. Global Parameters
3
38
L.P. Global Parameters
4
39
L.P. Global Parameters
5
40
L.P. Global Parameters
6
41
L.P. Global Parameters
7
42
L.P. Global Parameters
Summary
• Global parameter options dictate the overall philosophy of how Linear programming
creates production circuits and feed rates.
• In undertrucked situations you must set the Allow Unused Trucks in Undertrucked
Situations (L.P. MATCHTRUCKS) option to best meet your production plan.
• When the Allow Unused Trucks in Undertrucked Situations (L.P. MATCHTRUCKS) option
is set at YES you can use any of the other L.P. Config options
• When the Allow Unused Trucks in Undertrucked Situations (L.P. MATCHTRUCKS) option
is set to NO, L.P. ignores Proportional Feeding and shovel priorities.
43
L.P. Global Parameters
Summary
• When the Global Truck Productivity Objective is set to yes then L.P. will favor bigger
trucks to bigger shovels and smaller trucks to smaller shovels based on L.P. truck size.
• You can use the Proportionally Share Materials Dumping Capacities among Shovels
option to ensure that no shovels go unused because of constrained dumping locations.
• The Allow Truck Flows Between Ore and Waste option allows segregation of waste and
ore operations.
• The Use Global Material Priority option allows you to change the current global
material priority scheme – Ore equals Waste, Ore above Waste or Waste above Ore.
44
B.P, L.P & D.P
L.P. AVERAGE TRUCK
2200 + 1000
= 3200/#of trucks (20)
= 160t L.P. Average truck size
45
Priorities & Utilization
PRIORITY SCHEMES
There are two types of priority schemes available to the dispatcher……….
• Global Priority
• Direct priority
46
Priorities & Utilization
GLOBAL PRIORITY SCHEMES
Direct ranking is
turned off
Assign by
priority is
turned to “yes” The global priority scheme
becomes accessible. The dispatcher
then sets the priorities on each
shovel and material type to “high,
normal or low”
48
Priorities & Utilization
GLOBAL PRIORITY SCHEMES
When using the Global priority scheme, material will be weighted and
favored differently in each of the three schemes.
49
Priorities & Utilization
DIRECT PRIORITY SCHEMES
Direct ranking is
set to “yes”
Assign by
priority is
turned to “yes” The direct priority scheme becomes
accessible. The dispatcher then sets
the priorities on each shovel based on
a 1-10 ranking system
50
Priorities & Utilization
DIRECT PRIORITY SCHEMES
The direct ranking system is simpler and more flexible than the global
system. It allows for direct ranking of shovels from 1-10. Shovels can
also share a priority (i.e. two or more shovels sharing priority 1).
51
Priorities & Utilization
THE TIE BREAKER
52
Priorities & Utilization
UTILIZATION OR COVERAGE FACTORS
Utilization or coverage
feed rates are based on a
percentage factor of a
shovels dig rate.
53
Priorities & Utilization
UTILIZATION OR COVERAGE FACTORS
54
B.P, L.P & D.P
DYNAMIC PROGRAMMING
The third model in the DISPATCH® systems 3 model optimization strategy is
D.P. or Dynamic Programming. It uses the L.P. “Master Plan” as a reference.
D.P. builds Truck and Shovel need lists. D.P. works to achieve “balance and
synchronization” while meeting the L.P. flow rates. If D.P. is unable to
achieve the L.P. “Master Plan” it will favor high production, short haul
circuits. Focusing on the least amount of lost tonnage.
55
B.P, L.P & D.P
DYNAMIC PROGRAMMING
D.P. also handles loaded assignments. Assigning trucks to a dumping
location if the dump is ready and accepts the material type.
If no locks, the truck is sent to the neediest loaded L.P. path originating
from the shovel that just loaded the truck.
Usually the closest dump that is ready and accepts the material type.
56
B.P, L.P & D.P
57
Unlocking Locks & Bars
1. Truck requests an
assignment.
D.P. LOGIC FLOW
4. Build a list of empty paths 7. Is the first shovel in the shovel path list
ranked by shovel need. over trucked?
2. Create a snapshot of
the haulage operation Terminate
including truck and 5. Build a truck process NO YES
shovel positions assignment list
15, Save the 17. Does 11. Select the best 9. Select the best
YES truck assignment to shovel assignment
assignment as another truck
expected. require an that shovel and and allocate that
assignment? NO allocate the truck. truck to that shovel
path.
16. Issue the
truck NO 14. Does the truck 13. Remove the truck
assignment require a real-time from the assignment 12. Re-order the
assignment? list. shovel path list.
YES
58
Unlocking Locks & Bars
DUMP LOCK HIERARCHY
GRADE LOCK
SHOVEL LOCK
Because L.P. does not consider locks or bars when calculating the L.P.
solution, if you do not use locks and bars (whenever possible) then the L.P.
solution will be achievable.
For the same reason, it is best practice to avoid manually assigning trucks. If
a manual assignment needs to be done it is far better to “pre-assign” a truck
while it is still on the loaded side of the path. D.P. can deal with this type of
assignment in a cleaner and more efficient manner.
60
DISPATCH® Level I
Solution: BP LP & DP – 1
Module: Understanding the Algorithms – 1
Unit: Fleet Management – 00