p-ISSN 2980-4868 | e-ISSN 2980-4841
Optimizing Coal Production Estimates:
Balancing Topographic Surveys Method and Truck Counts Method at Pit Kress, PT.
Bordun Indie, South Kalimantan, Indonesia
Sandi Kurniawan1*, Liane Okdinawati2
Institut Teknologi Bandung, Indonesia
ABSTRACT
Accurate coal production estimation is essential to support efficient
decision-making and operational success in the mining industry. Discrepancies
between estimation methods, such as truck counts and topographic surveys, often
lead to inefficiencies and failure to achieve production targets. This research
aims to identify the root causes of such discrepancies at PT Bordun Indie and
propose effective solutions to improve the accuracy of production estimation.
Using the DMAIC (Define, Measure, Analyze, Improve, Control) methodology, this
research analyzes critical factors such as human error, absence of standard
operating procedures (SOPs), and reliance on manual data entry. Descriptive
statistical approach and linear regression analysis were used to measure the
variation and relationship between the two estimation methods. The results
showed that the implementation of process standardization, digital technology
integration, and continuous monitoring significantly reduced data variability,
thereby improving the accuracy of production estimation. The implications of
this research are not only relevant for PT Bordun Indie, but can also be widely
applied in the mining industry to optimize production planning, improve
decision-making, and support better achievement of production targets. This
research confirms the importance of systematic improvement to drive operational
efficiency and sustainability in the mining sector.
Keywords: Coal Production,
Deviation, DMAIC Framework, Truck Counts Method, Topographic Survey Method.
INTRODUCTION
The coal mining industry is
a vital sector supporting the global economy (Fitriyanti, 2016), including in Indonesia. PT. Bordun Indie, as one of the
leading mining companies, has set an ambitious target to increase coal
production from 46.8 million tons in 2024 to 54 million tons the following
year. To achieve this target, careful planning and effective operational
strategies are needed. One of the crucial elements of good mine planning is the
availability of accurate and reliable production data, which is used for
performance evaluation, planning, and data-driven decision-making (Shaddad et al., 2024).
The two main methods used to
measure coal production are truck count estimation and topographic surveys (Prasmono, 2015). Estimating the number of trucks involves calculating
the amount of material transported based on the number of truck trips from PIT
Kress to ROM stockpile. Although this method is often used due to its
convenience and relatively low cost, it has a drawback in terms of accuracy. In
contrast, topographic surveys use well-calibrated measuring tools such as Total
Station and Real Time Kinematic, resulting in more accurate data on the volume
of material in the field. However, based on production data from 2020 to July
2024, it was found that the data from the truck counting method was highly
volatile, with deviations that often exceeded the accepted tolerance limit of
less than 5%.
Descriptive statistics are
used to analyze the variance of the measurement results of each method by
calculating descriptive measures such as variance and standard deviation (Vivi Silvia, 2020). These steps help identify data fluctuations and
determine methods with greater variance as objects of further research. The
expected result is that the variance in the estimated number of trucks is close
to the variance of the topographic survey results, indicating that the
fluctuations in both methods are relatively similar.
In addition, linear
regression analysis was applied to evaluate the relationship between the
measurement methods (Maulud & Abdulazeez,
2020). The estimate of the truck counts is used as a dependent
variable (Y), while the results of the topographic survey method as an
independent variable (X). The purpose of this analysis is to ascertain the
linear relationship between the two methods and to measure how well the survey
results can explain the variation in the truck counts method. An expected
R-square value of more than 0.95 indicates that topographic surveys can account
for more than 95% of the variation in the truck counts. This high R-squared
value is important because it ensures that linear regression models are highly
accurate in explaining the relationship between the two methods, which has an
impact on the reliability of coal production estimates and decision-making in
companies.
Figure 1. Coal production from
January 2020 to July 2024
The inaccuracy of production data
generated by the truck counts method can be caused by a variety of factors,
including truck capacity variability, inaccuracies in the weighing process, and
human error (Bepswa,
2016). Meanwhile, data from topographic surveys
that tend to be more stable and accurate show more consistent results.
Therefore, this research aims to evaluate the fluctuations between the truck
counts and topographic surveys in coal production measurements, as well as
identify strategies to correct the causes of significant deviations. By
maintaining deviations within the accepted tolerance limits, it is hoped that
production planning can be more optimal, thereby supporting the achievement of
higher production targets in the future.
In conducting
this research, it was found that similar research had been conducted on
overburden, whereas this research specifically focused on the discrepancy
between the truck counts and topographic surveys in estimating coal production.
Based on research conducted by (Kurnia et
al., 2015), it is known that the cause of the
difference between the truck counts method and the topographic survey of the
volume of the removed overburden occurs due to the use of inaccurate constants,
the neglect of equipment filling factors, the assumption of uniform truck
loads, and unideal operating conditions such as sludge materials that reduce
carrying capacity.
Based on the
above background, the objective of this research is to evaluate the difference
between production estimation methods using truck counts and topographic
surveys, and identify the factors that cause significant discrepancies in
results. This research also aims to formulate improvement strategies that can
increase the accuracy of coal production estimation and keep the measurement
results within acceptable tolerance limits. The benefits of this research are
to provide solutions that can be implemented to reduce the variability of
production estimation data, improve mine planning efficiency, and support the
achievement of higher production targets. In addition, this research is
expected to be a reference in improving the reliability of production
measurements in the mining industry in general, as well as encouraging more
optimal use of technology and standard procedures to support data-based
decision making.
RESEARCH METHOD
This research adopts a mixed-methods approach, integrating both
quantitative and qualitative data to thoroughly analyze the deviations in coal
production estimates between the truck count method and the topographic survey
method. The DMAIC (Define, Measure, Analyze, Improve, Control) framework from
Six Sigma is utilized to enhance estimation accuracy and reduce discrepancies
between these two methods (Lemke &
Strulak-Wójcikiewicz, 2021). The detailed steps are outlined below.
1) Define: In this phase, the problem was
identified as the inconsistency in coal production estimates when comparing the
truck count data with topographic survey data. The objective is to pinpoint the
primary causes of this deviation and set clear goals for improvement.
2) Measure:
During the measurement phase, data was collected using both qualitative and
quantitative methods to capture a holistic view of the factors contributing to
estimation discrepancies.
a. Qualitative Methods: Interviews with key
stakeholders, observations of the data collection process, and discussions
helped to identify procedural gaps and potential sources of human error, such
as the lack of standard operating procedures (SOPs).
b. Quantitative
Methods: Historical data, including demurrage, truck count, and summary volume,
was gathered. Specific measurements included density sampling and truck count
sampling, along with accuracy tests and calibration processes. These
quantitative measures were essential for evaluating variations between the
methods and ensuring data precision.
3) Analyze: In
the analysis phase, both descriptive statistics and linear regression analysis
were employed to investigate the relationship and variation between truck count
data and topographic survey data.
a. Descriptive
Statistics: This analysis was chosen to summarize the data and provide a clear
view of variability and central tendencies, which allowed for identifying
patterns and anomalies in the data.
b. Linear
Regression Analysis: Linear regression was used to examine the correlation
between truck count data and topographic measurements, allowing for a deeper
understanding of the consistency between these methods. This method was
selected due to its ability to predict outcomes based on existing variables,
providing insights into the reliability of the truck count method as an
estimator.
4) Improve:
Based on the findings from the analysis, specific improvement strategies were
implemented. These included the standardization of processes, the integration
of digital technologies to reduce manual entry errors, and the development of
SOPs to ensure consistency in data collection.
5) Control:
Finally, a control phase was established to maintain the improvements achieved.
Continuous monitoring and periodic reviews were set up to ensure ongoing
accuracy in production estimation and prevent future deviations.
Figure 2. Research Design
RESULT AND
DISCUSSION
Define
This
research started from the main problem, namely the fluctuating deviation
greater than 5% and smaller than -5% between the estimated coal production
using the truck count method and the results of topographic survey measurements
at the Pit Kress PT. Bordun Indie during 2020 to July 2024. Such deviations
have a significant impact on the accuracy of production reporting and have the
potential to cause financial losses for the company, including errors in sales
planning that can result in additional costs such as demurrage. Therefore, the
project aims to reduce the deviation between the two measurement methods to less
than ±5%.
Customer
needs are identified through a Voice of the Customer (VOC) approach, where data
users express the need for a more accurate and efficient reporting system (Freeman &
Radziwill, 2018). Production teams need reliable estimates to
support operations, while marketing requires the right data for marketing and
shipping planning (Rao, 2023). The management also hopes that the difference
between daily production data based on truck count and survey results will be
minimal to ensure production accuracy and prevent sales planning errors.
The
scope of activities includes collecting data from the Pit to ROM Stockpile,
topographic survey measurements, and data recording in the Pit Kress, with the
exception of activities outside the pit, such as measurements in other areas or
the use of Weigh in Motion (WIM).
A
process map (SIPOC) is created to understand the overall process flow, which
identifies suppliers, inputs, processes, outputs, and customers of the existing
system.
Table
1. SIPOC of the Production Reporting Process
Supplier |
Input |
Process |
Output |
Customer |
|
Hauler's
Operator |
Trip
information, time sheet form |
Report
information via radio, manual report collection |
Trip
report |
Dispatcher |
|
Dispatcher |
Truck
count data from operator hauler |
Entering
and sending data in Excel format to Operation Control Centre Engineer |
Dispatch
report |
Operation
Control Centre (OCC) |
|
Operation
Control Centre (OCC) |
Dispatch
report |
Data
verification & reconciliation |
Production
report |
Reporting
officer |
|
Reporting
Officer |
OCC
Report |
Input
into daily production report format |
Daily
production report |
Production
Supervisor, Mine Plan Engineer, Geologist, ROM and Hauling Supervisor,
Marketing, Management |
|
Topographic
Surveyor |
Raw
data |
Data
validation and processing |
Summary
volume report |
Reporting,
Officer, Production Supervisor, Mine Plan Engineer, Geologist, ROM and
Hauling Supervisor, Marketing, Management |
Data collection and production reporting begins with
the Hauler Operator, who reports trip information via radio, which is then
manually recorded. The Dispatcher enters this trip data into an Excel format
and sends it to the Operation Control Centre (OCC) for verification and
reconciliation, resulting in a Production Report. The Reporting Officer
processes this report into a daily production report used by various
stakeholders, including the Production Supervisor, Mine Plan Engineer,
Geologist, ROM and Hauling Supervisor, Marketing, and Management. Meanwhile,
the Topographic Surveyor validates and processes raw data to produce coal volume
and tonnage information utilized by the Operation, Finance, Geologist, and
Management divisions, ensuring that the process runs accurately and supports
efficient decision-making.
Measure
In
the Measure stage in this research, the main focus is to collect quantitative
and qualitative data needed to understand the cause of the deviation between
the estimated coal production using the truck count method and topographic
survey measurements in the Pit Kress of PT. Bordun Indie. Quantitative data is
collected from various secondary and primary sources, such as daily production
reports that record truck count data (January 2020 to July 2024 period), volume
summary reports (January 2020 to July 2024 period), and truck count sampling
data for each hauler unit. To measure the density of coal, density test data is
obtained from drilling results (secondary data) and grab sampling (primary
data), while the accuracy of measuring instruments such as total station (TS)
and Real Time Kinematic (RTK) is tested through the collection of primary data
to ensure the accuracy of the survey results.
In
addition to quantitative data, qualitative data is also collected through SOP
Sampling truck count analysis as secondary data to understand the operational
standards applied. Direct observation of the process of recording and reporting
truck count data is carried out to identify potential errors in recording in
the field. Discussions with relevant stakeholders, including operators,
dispatchers, surveyors, and management, are conducted to gain insight into
operational challenges and the factors that affect data accuracy. This Measure
stage provides a strong foundation for analyzing the root cause of deviation by
combining quantitative and qualitative data, which will then be used for
improvement at the Analyze and Improve stage (Nurazizi, 2023).
Figure
3. Monthly Deviation
The
graph above (Figure 3) illustrates the monthly deviation between the estimated
coal production using the truck count method and the results of the topographic
survey at the Pit Kress of PT. Bordun Indie from January 2020 to July 2024,
with the red line showing the difference between the two measurement methods
and the dotted line as the upper and lower control limits (UCL) and lower (LCL)
at ±5%. Significant fluctuations in the graph, with peak deviations reaching
-30% and 26%, indicate high instability and variability in the measurement
process
Descriptive
statistical analysis (Table 2) shows that the average production estimated by
the truck calculation method is 842,423 tons, while by the survey method, it
reaches 859,382 tons. The high variance in the truck count method of
42,897,405,529 compared to the survey method of 34,725,365,544 indicates a
greater fluctuation in truck data recording. This significant standard
deviation indicates the data instability of the truck counting method.
Table
2. Descriptive Analysis
|
|
Truck Count |
Survey |
|
Mean |
842,423 |
859,382 |
|
Standard Error |
27,928 |
25,127 |
|
Median |
858,447 |
884,543 |
|
Standard Deviation |
207,117 |
186,347 |
|
Sample Variance |
42,897,405,529 |
34,725,365,544 |
|
Kurtosis |
-0.24 |
-0.05 |
|
Skewness |
-0.27 |
-0.42 |
|
Range |
900,391 |
879,331 |
|
Minimum |
376,539 |
337,926 |
|
Maximum |
1,276,930 |
1,217,257 |
|
Sum |
46,333,240 |
47,265,983 |
|
Count |
55 |
55 |
Linear regression is used to analyze the linear
relationship between topographic surveys (independent variables) and truck
counts (dependent variables) to evaluate the reliability of truck count
estimates. This method measures how much variation in truck counts is explained
by the survey, indicated by the R˛ value indicating the strength of the
relationship, and allows prediction and identification of deviations for
process improvement.
The scatter plot graph (Figure 4) shows an R˛ value
of 0.8474, which means that 84.74% of the truck count variation is explained by
the topographic survey, indicating a strong relationship between the two
methods, but there is still 15.26% unexplained variation due to operational
factors, procedural differences, or recording errors, so this analysis is
essential for improving the recording process and improving the accuracy of
estimation.
Figure 4. Scatter
plot shows the linearity of truck counts and topographic survey
Based on the analysis of the measurement results,
the comparison between the truck count method and the topographic survey in the
Pit Kress of PT. Bordun Indie from January 2020 to July 2024 shows significant
variability and instability in coal production estimates. The monthly deviation
graph shows peak fluctuations reaching -30% and 26%, exceeding the acceptable
control limit of ±5%, which indicates a high inconsistency in the truck count
method. Descriptive statistical analysis showed a high variance in the truck
count data of 42,897,405,529 compared to the survey of 34,725,365,544, showing
the instability of the truck count method data. The scatter plot analysis
showed an R˛ value of 0.8474, which means that 84.74% of the variation in the
truck count estimate could be explained by the topographic survey, but 15.26%
of the unexplained variation showed the influence of operational factors,
procedural inconsistencies, and recording errors. The factors that affect this
instability will be explained in more detail in the analysis stage.
The
accuracy measurement for the two topographic survey instruments, Total Station
and RTK, has been carried out by measuring 20 identical points with both
instruments. Based on the scatter plot, an R2 value of 0.9917 was obtained.
This means that the two measurement tools have a very strong linear
relationship and very high accuracy. In other words, both instruments provide
nearly identical and highly consistent results when measuring the same points.
Figure 5. Scatter
plot shows the linearity of both topographic measurement tools
Analysis
The
analysis stage aims to identify the root cause of significant deviations that
occur between the estimated coal production using the truck calculation method
and the survey method. Based on the data collected at the measure stage,
descriptive statistical analysis, linearity test, and Ishikawa chart analysis
were carried out to understand the main factors that contributed to the
deviation.
Figure
6. Root Cause Analysis (Ishikawa)
Ishikawa's
diagram (Figure 6) illustrates the various potential causes of truck count
deviations of more or less than 5%, which are grouped into five main
categories: Methods, People, Materials, Machinery, and Environment (Juliandra, 2022).
In
the human category, there are several significant operational errors, such as
the operator's lack of accuracy in trip calculating, manual recording errors by
hauler operators, and misinterpretation of information by dispatchers.
Dispatchers often make mistakes in entering data due to unclear reporting via
radio, inconsistencies between radio reports and manual records, and lack of
focus in carrying out tasks (Dash, 2023).
In
category of methods, key issues include the absence of Standard Operating
Procedures (SOPs), reliance on manual recording, and low data awareness. The
use of outdated references, such as default density and truck factors that are
not derived from actual sampling tests, highlights critical gaps in data
management and procedural standardization, leading to significant human errors.
In
terms of materials, the difference in the amount of load on the same truck type
is often based only on visualization and not on accurate measurements. This
condition is exacerbated by the presence of puddles on the coal front, which
can cause the survey team to fail to take data, so that the coal that has been
taken from the area cannot be measured properly.
For
the machinery category, the failure of survey equipment is the main cause,
mainly due to lack of maintenance and obsolescence of the equipment. In
addition, the lack of supporting technology in recording truck count data also
magnifies the potential for errors because processes that still rely on manual
recording are prone to errors.
Finally,
in the environmental category, poor weather conditions play a major role in
disrupting the visibility and accuracy of measurements. The effects of noise
from the mine area can affect communication between hauler operators and
dispatchers, increasing the likelihood of misinformation in reporting. Overall,
the truck count deviation is caused by a combination of these factors,
indicating the need for improvements in procedures, increased training,
integration of more modern technologies, and handling of operational conditions
to improve data accuracy and production efficiency.
Improve
The
Improve stage focuses on the development and implementation of improvement
solutions to address the root cause of deviations in the estimated coal
production that have been identified in the analysis stage. Based on the
results of the previous analysis, improvements are directed to errors in
recording and reporting data caused by human factors and the absence of
standard operating procedures (SOPs). The goal of this stage is to reduce data
variability and ensure that the process of recording and reporting production
data becomes more accurate and consistent.
1.
Standardization of Recording and Reporting
Procedures.
The first step taken is to develop a clear and
standardized SOP for the process of recording and reporting coal production
data. This SOP is designed to ensure that all operators follow the same
procedure when recording the number of truck trips and the volume of coal
transported. The new procedures also include guidance for accurate data
filling, data verification steps, and error reporting mechanisms that can be
quickly identified and corrected. With this SOP, it is hoped that consistency
and accuracy in data recording will increase.
2.
Training
The training includes several key aspects: first,
understanding SOPs, where participants are educated about the new standard
procedures, including how to record data, verification steps, and error
reporting mechanisms. Second, training on the use of digital technology, which
involves the use of automated sensors and monitoring dashboards, as well as
handling potential technical issues. Third, providing knowledge on best
practices in data recording and reporting to ensure accuracy and consistency
throughout the process. With comprehensive training, it is expected that each
team member will be able to execute the new procedures and effectively utilize
digital technology correctly (Sujadi, 2024).
3.
Implementation of Digital Technology (Internet of
Things) for Data Recording
To reduce the reliance on error-prone manual input,
Internet of Things (IoT) technology has been widely used for real-time
monitoring of the environment, safety and production (Zhang et al., 2023). Digital technology can be applied in the recording
of production data. The use of automated sensors and digital systems to record
the number of trucks and the volume of coal at each hauling point allows the
data to be directly stored in the system without human intervention. The technology
is integrated with a dashboard monitoring and monitoring system that allows
production and management teams to monitor data in real-time, detect
non-conformities, and make corrections quickly. The application of this
technology also reduces the time required for data reporting and improves
overall operational efficiency.
Since 2022, PT. Bordun Indie has implemented a Fleet
Management System based on IoT technology to monitor coal transportation
activities from ROM stockpile to Port stockpile. This concept can also be
applied to all mining activities in PIT Kress.
4.
Routine Supervision and Audit.
To ensure that the improvements made can be
sustained and have a sustainable impact, periodic monitoring and audits are
carried out in the recording and reporting process. The supervisory team is
tasked with randomly checking the data that has been recorded by the operator
and comparing it with data from the digital system. This audit aims to ensure
that SOPs are followed correctly and that there are no significant deviations
in the reported data (Lemke &
Strulak-Wójcikiewicz, 2021). Manual recording needs to be continued until the
digital system can run as well as expected.
Research
is still ongoing to this day. To assess the success of this improvement, a
discussion was carried out with the Operational Control Centre team. The
implementation of digitalization, process standardization, and continuous
monitoring is predicted to reduce the deviation to close to 3%. Digitalization
will reduce errors caused by human factors, while standardization of procedures
will improve methodologies and reduce deviations (Fauzi, 2020). In addition, training for operators and teams
involved in data processing will improve their understanding of procedures and
the importance of data accuracy (Firoozi et al.,
2024).
Control
At
this stage, control measures are implemented to maintain the consistency and
accuracy of coal production data recording, as well as prevent the recurrence
of significant deviation problems. Good controls will ensure that repairs are
not only temporary but become an integral part of the operational process.
1.
Implementation of Process Control through Procedures
and Monitoring
To keep the procedures that have been implemented
consistently followed by all operators, a continuous monitoring system has been
created. Procedures are used as a standard reference in every production
recording and reporting activity, and operators are required to undergo regular
refreshment training sessions. The dashboard-based real-time monitoring system
allows production and management teams to monitor the recording data in
real-time. Deviations from the record-keeping standards can be detected quickly
and corrective action can be taken immediately.
2.
Using Control Charts to Monitor Recording
Performance
Control charts are used as statistical control tools
to monitor variations in production, recording data continuously. This graph
helps the team to identify if there is a trend of deviation or fluctuations
that go out of the predetermined control limits. By using control charts, teams
can immediately know if there are anomalies that require intervention before
they further impact the accuracy of production data. If the monthly deviation
is greater than 5% or less than -5%, then the cause of the deviation needs to
be known for improvement. The scatter plot can be used as another indicator to
monitor the deviation between these two methods. If the R squared is less than
0.95, then it is necessary to explore further the cause of the deviation.
However, if the R squared is above 0.95, then the deviation is acceptable. Continuous analysis of the control chart data
also helps dynamically adjust the process according to field conditions.
3.
Periodic Data Audit and Performance Evaluation
The routine audit process of recording and reporting
production data continues as part of the control measures. Audits are carried
out randomly and scheduled to ensure that the data reported is in accordance
with conditions in the field and follows the standards that have been set. The
audit results are used to provide feedback to operators and management
regarding compliance with procedures and the effectiveness of the implemented
recording system. This performance evaluation is also the basis for making continuous
improvements and identifying areas that need further improvement (Nurazizah, 2018).
4.
Formation of Supervisory Team and Feedback Loop
A supervisory team was formed to monitor SOP
compliance and implement process control. This team is tasked with providing
guidance to operators, managing data from the monitoring system, and analyzing
detected deviations (Ummah, 2024). The structured feedback loop allows operators to
report on obstacles encountered in the recording process, and management can
quickly take the necessary corrective steps. This system also encourages the
active involvement of operators in maintaining the quality of production data.
CONCLUSION
The
conclusion of this research shows that the truck count method has a greater
variance than the topographic survey, indicating the need for improved accuracy
in estimating coal production at Kress Pit, PT Bordun Indie. The main causes of
this discrepancy are human error due to non-standardized recording procedures,
the use of manual methods, and the use of external reference-based truck
factors that do not match the site conditions. The proposed solutions include
standardization of procedures through SOPs, specialized training,
implementation of IoT technology for real-time data collection, and regular
audits to improve data reliability and operational efficiency. This research
contributes to future research as a foundation for the implementation of a more
accurate production recording system in the mining industry. However, the scope
was limited to the Kress Pit, so the findings need to be tested in other mining
areas to examine their applicability under various operational conditions.
Long-term research into the impact of digitization, particularly the
integration of IoT technologies, is expected to reveal the huge potential for
improving the efficiency and accuracy of production data, providing strategic
insights for the management of the mining industry at large.
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Sandi Kurniawan, Liane Okdinawati (2024) |
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First publication right: Asian Journal of Engineering, Social and Health (AJESH) |
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