Kaizen From April 20183

No Vertical Unit Kaizen ID Kaizen Title
5570 Mines RDM MNS/RDM/KZN/201819/001 Savings in purchase of cartridge

ARRANGEMENT FOR SAFETY OF 1220 BELT
6111 Mines RDM MNS/RDM/KZN/201819/002 CONVEYOR
1220 HEAD SNUB PULLEY CHANGE 2-3 HR
6112 Mines RDM MNS/RDM/KZN/201819/003 EARLY AS PLANNED
G-80 modified with G-100 casing and
6155 Mines RDM MNS/RDM/KZN/201819/004 impeller.
3/4 inch pipe was aranged for pump jam
6156 Mines RDM MNS/RDM/KZN/201819/005 removal
6176 Mines RDM MNS/RDM/KZN/201819/006 Pump performance increase
Better access for water control for filling

cyclones trough to reduce water injection in
6178 Mines RDM MNS/RDM/KZN/201819/007 FST
Fill MCC water control level control to avoid

6179 Mines RDM MNS/RDM/KZN/201819/010 plant tripping
To avoid tailing lines leakage above fill plant

6180 Mines RDM MNS/RDM/KZN/201819/009 transformer area
6181 Mines RDM MNS/RDM/KZN/201819/008 Cleaning of SIPX tank

Improved illumination by installing LED
6186 Mines RDM MNS/RDM/KZN/201819/011 lights
Illumination improvement at new bore hole
6191 Mines RDM MNS/RDM/KZN/201819/020 site
6192 Mines RDM MNS/RDM/KZN/201819/019 welding chain in every gate end box
Arrangement of power source for diesel
6206 Mines RDM MNS/RDM/KZN/201819/012 pump as main cable failure occured
6207 Mines RDM MNS/RDM/KZN/201819/014 Installation of siren on flotation crane
Installtion of tullu pump with automation in

6208 Mines RDM MNS/RDM/KZN/201819/013 cable trench of fill plant mcc
6272 Mines RDM MNS/RDM/KZN/201819/018 Damage prevention of -35mRL Crane
Pull out test of exposed rock bolts for

6293 Mines RDM MNS/RDM/KZN/201819/016 hanging beams
Identification 2.4 m & 1.8 m rock bolt after

6294 Mines RDM MNS/RDM/KZN/201819/015 grouting
6332 Mines RDM MNS/RDM/KZN/201819/017 rerouting of EOT cable in crusher
Installation of density meter at tailing pump

6334 Mines RDM MNS/RDM/KZN/201819/021 redundant line
Drain valve replaced with 3 inch socket and
6352 Mines RDM MNS/RDM/KZN/201819/022 plug.
Installation of a Surface Drilling water line to

have the continuty of flow of water for
6370 Mines RDM MNS/RDM/KZN/201819/023 Drilling in VRM Section(150,125,100 Mrl)
6459 Mines RDM MNS/RDM/KZN/201819/024 Welding Machine :electrocution protection

6512 Mines RDM MNS/RDM/KZN/201819/030 Improvement in illumination range
Monitoring of Crusher screens for process

6513 Mines RDM MNS/RDM/KZN/201819/025 improvement and enhancing its avialibilty
6515 Mines RDM MNS/RDM/KZN/201819/026 In house repairing of Ball mill isolator switch
320m3 tank at PDO amperage shown in
6516 Mines RDM MNS/RDM/KZN/201819/027 scada at control room
Frequent burning of motor of P-7 water
6517 Mines RDM MNS/RDM/KZN/201819/028 recovery pump due to jamming
Local control stop switch provided near
6518 Mines RDM MNS/RDM/KZN/201819/029 magnet of 1085
6536 Mines RDM MNS/RDM/KZN/201819/031 Hammer Stand
Metal Hammer replaced with Plastic

6595 Mines RDM MNS/RDM/KZN/201819/037 Hammer for core extraction from inner tube
To change chute modification at 1085
6610 Mines RDM MNS/RDM/KZN/201819/032 conveyor
BALLOW HOSE REPLACED IN PLACE OF MS
6611 Mines RDM MNS/RDM/KZN/201819/033 LINE
6631 Mines RDM MNS/RDM/KZN/201819/034 TCS on Royalty Updation in 26 AS
Detail Cost review analysis and presentation

6632 Mines RDM MNS/RDM/KZN/201819/035 for cost review
Development saving by using unused X Cut

6662 Mines RDM MNS/RDM/KZN/201819/036 for Reserve station`
6671 Mines RDM MNS/RDM/KZN/201819/038 Reflector strip for parking

Reduction in failure coolant filter mounting
6673 Mines RDM MNS/RDM/KZN/201819/040 and hose
REDUCTION IN DAMGE TO AUTO LUBE
6674 Mines RDM MNS/RDM/KZN/201819/041 SYSTEM
6675 Mines RDM MNS/RDM/KZN/201819/039 Coating at Chemical Area
6676 Mines RDM MNS/RDM/KZN/201819/050 Rear Parking light mounting modification.
6677 Mines RDM MNS/RDM/KZN/201819/049 Re Shuffling of oil room and container
6678 Mines RDM MNS/RDM/KZN/201819/048 MU antena position change in new ST1030

Pneumatic greasing pump installed in
6679 Mines RDM MNS/RDM/KZN/201819/047 HEMM
MT436B -03 Steering cylinder rod covered
6680 Mines RDM MNS/RDM/KZN/201819/046 by conveyor belt.
6681 Mines RDM MNS/RDM/KZN/201819/045 Dust seal fitted in Bucket pin ST1030 -06
6682 Mines RDM MNS/RDM/KZN/201819/044 Dust seal fitted in Bucket pin ST1030 -06
Painting Done in Brake metal pipe MT436B-
6683 Mines RDM MNS/RDM/KZN/201819/043 02
6684 Mines RDM MNS/RDM/KZN/201819/042 Radiator mounting modification in ST 7
Use of spray paints instead of using manual

6688 Mines RDM MNS/RDM/KZN/201819/051 paints with Jutes
Production Drill hole marking with colour
6689 Mines RDM MNS/RDM/KZN/201819/052 and steel pegs
Water line laying for ball mill no-4 feed

6701 Mines RDM MNS/RDM/KZN/201819/056 chute
Providing stand for welding machine to

6715 Mines RDM MNS/RDM/KZN/201819/055 prevent damage from water splash
6717 Mines RDM MNS/RDM/KZN/201819/054 Use wrap seal to prevent pipeline leakage
6767 Mines RDM MNS/RDM/KZN/201819/053 WIRE PROTECTION

#SGA : Shifting of air conditioned Drill
6949 Mines RDM MNS/RDM/KZN/201819/057 Jumbo Sandvik DD321 in RDM-UG
#SGA- online arresting the oil leakage in
6951 Mines RDM MNS/RDM/KZN/201819/060 1.5MVA transformer
monitoring of shaft inset CCTV camera on

6952 Mines RDM MNS/RDM/KZN/201819/059 mobile phone
1295 crusher centrifuge pump fitted &
6964 Mines RDM MNS/RDM/KZN/201819/058 taken in circuit
# SGA-Stripping of 350m in 100mRL Main

7110 Mines RDM MNS/RDM/KZN/201819/061 drive to facilitate more space in the drive
# SGA-Ventilation problem in lower east

7111 Mines RDM MNS/RDM/KZN/201819/062 lode section
# SGA-To study and reduce the Blast cycle
7138 Mines RDM MNS/RDM/KZN/201819/063 time
Alternative source of filling 180mRL Stope-

351 and thus not laying 500m HDPE pipeline
for filling saving Manpower and reducing
7151 Mines RDM MNS/RDM/KZN/201819/064 NVA
#SGA-To draw power cable from -87mRL to

-65mRL through Borehole for Operation of
7271 Mines RDM MNS/RDM/KZN/201819/065 Jumbo , solo & Aux fan
7351 Mines RDM MNS/RDM/KZN/201819/066 Safety guard made at jaw crusher
Retrofitting of reagent/chemical area crane

7505 Mines RDM MNS/RDM/KZN/201819/068 by flame proof crane
Fill Plant Transformer area Site improvement

7507 Mines RDM MNS/RDM/KZN/201819/067 to increase safety and reliability
7617 Mines RDM MNS/RDM/KZN/201819/070 Dust control from exhaust of MT436B
Partition between engine and steering

7619 Mines RDM MNS/RDM/KZN/201819/069 pump
SCRREN U/D PANEL CHANGE WITH MODIFY
7647 Mines RDM MNS/RDM/KZN/201819/071 INHOUSE PLATE
HEMM Waste Transport Procedure
7729 Mines RDM MNS/RDM/KZN/201819/073 Improvement
Shifting the grinding and floation area

welding machine on stand to save them
7740 Mines RDM MNS/RDM/KZN/201819/072 from damage while hosing the area
7807 Mines RDM MNS/RDM/KZN/201819/074 Increasing communication in NL
7810 Mines RDM MNS/RDM/KZN/201819/075 Stand for radiatopr frame
7812 Mines RDM MNS/RDM/KZN/201819/076 Direction of LHD movement
7814 Mines RDM MNS/RDM/KZN/201819/077 maintennace bay at door of container
7816 Mines RDM MNS/RDM/KZN/201819/078 zero power isolation in equipment
7817 Mines RDM MNS/RDM/KZN/201819/079 Turning of HEMM in workshop

7826 Mines RDM MNS/RDM/KZN/201819/080 Emergecy switch at Remote working
DAMAGE PROTECTION TO HOSES AND
7827 Mines RDM MNS/RDM/KZN/201819/081 ELECTRICAL ITEMS
Provision of greasing system in ST1030
7837 Mines RDM MNS/RDM/KZN/201819/082 radiator fan hub
Replacing the 6 inch foot valve to 4 inch foot

7843 Mines RDM MNS/RDM/KZN/201819/083 valve for compressor house pump
EXTRA LINE CONNECTED TO OLD FST FOR
7931 Mines RDM MNS/RDM/KZN/201819/084 CONTINUOUS FILLING.
Installation of load cell in Mill EOT cranes for

7962 Mines RDM MNS/RDM/KZN/201819/087 display of Load being lifted by crane
Installation of proximity switch for providing

Dumper dump body positioning status in
7963 Mines RDM MNS/RDM/KZN/201819/086 driver cabin by siren to enhance safety
Electrical damaged Panel replacement of 5

7964 Mines RDM MNS/RDM/KZN/201819/085 ton MCC side Crane
Replacement of 5 Ton MCC side and 5 Ton

Filter side crane lifting hook and wire rope
to enhance safety as latch were not
7965 Mines RDM MNS/RDM/KZN/201819/089 available in old look
Replacement of OLD ball Mill 3 conventional

type LRS by Vapromatic type LRS to save
7966 Mines RDM MNS/RDM/KZN/201819/088 water leakage and enhance safety
Illumination improvement near Tailing
battery and cement mising tanks to enhnace
7967 Mines RDM MNS/RDM/KZN/201819/091 safety while opening the manual valve
Installation of flame proof loght in grease

7968 Mines RDM MNS/RDM/KZN/201819/090 and lubricant room to enhance fire safety
Provide oil level indication in control room
7971 Mines RDM MNS/RDM/KZN/201819/092 for 1296 crusher.
7972 Mines RDM MNS/RDM/KZN/201819/094 1220 Take up structure Restrengthen
7973 Mines RDM MNS/RDM/KZN/201819/093 Provide lock spring in 1296 Crusher
8009 Mines RDM MNS/RDM/KZN/201819/098 1085 DISCHARGE CHUTE MODIFICATION
8010 Mines RDM MNS/RDM/KZN/201819/097 1085 DECK PLATE FIXING WORK

RALLING & TOE GUARD PROVIDED AT
8011 Mines RDM MNS/RDM/KZN/201819/096 SCREEN HOUSE
8012 Mines RDM MNS/RDM/KZN/201819/095 lADDER TO BE MODIFY AT SCREEN HOUSE
8166 Mines RDM MNS/RDM/KZN/201819/100 Mixing tank drain plug direction changed.
seperate line placed for 7300B recirculation

8167 Mines RDM MNS/RDM/KZN/201819/099 pump
Crusher crane current carring wheel inhouse

8176 Mines RDM MNS/RDM/KZN/201819/104 modification work
Aligned compound delivery header to

ensure uniform lubrication of ball mill girth
8178 Mines RDM MNS/RDM/KZN/201819/103 gear.
Replacing FST cyclone feed nipple with
8179 Mines RDM MNS/RDM/KZN/201819/101 HDPE nipple
The ckt-4 cleaner distribution box height
8185 Mines RDM MNS/RDM/KZN/201819/102 increased
Provision of Seperate Stop push button near
8208 Mines RDM MNS/RDM/KZN/201819/107 field operator
Shiftting of Pull card above conveyor guard

8209 Mines RDM MNS/RDM/KZN/201819/106 at 1270 conveyor
8210 Mines RDM MNS/RDM/KZN/201819/105 Provision of antipanic gate in MCC

Provision of hooter alarm for sodium
8212 Mines RDM MNS/RDM/KZN/201819/109 cyanide
Provide the auto drainner system in

8213 Mines RDM MNS/RDM/KZN/201819/108 compressor air tank
8215 Mines RDM MNS/RDM/KZN/201819/113 Shifting of AC out door unit at ground level
8216 Mines RDM MNS/RDM/KZN/201819/112 Proper storage of arc flash dress

Arrangement of keeping the rescue hook &
8217 Mines RDM MNS/RDM/KZN/201819/111 earthing rod in MCC
8218 Mines RDM MNS/RDM/KZN/201819/110 ELR system provision in drill m/c supply
Fire Alarm system/smoke deductor provide

8223 Mines RDM MNS/RDM/KZN/201819/116 in MCC & chemical area
Illumination to be improve in vaccume
8224 Mines RDM MNS/RDM/KZN/201819/115 pump area
RCC stand to be made for UPS/server
8225 Mines RDM MNS/RDM/KZN/201819/114 Battery bank
Removal of joints for ball mill area pedestal

8226 Mines RDM MNS/RDM/KZN/201819/117 fan and switch boards
8299 Mines RDM MNS/RDM/KZN/201920/004 welding cable joint
8300 Mines RDM MNS/RDM/KZN/201920/003 LIP plate devlopment at local workshop

8301 Mines RDM MNS/RDM/KZN/201920/002 High boom support
Increasing Cooling Efficiency of Diamec

PHC4 machine to Improve Operational
8313 Mines RDM MNS/RDM/KZN/201819/118 Efficiency
Increased machine availability of U4

Exploration Drill Machine by Replacement of
8408 Mines RDM MNS/RDM/KZN/201920/001 existed Air cooler
Making a provision of cylinder's stand at

8686 Mines RDM MNS/RDM/KZN/201920/014 underground garage to prevent from fall.
Making a provision of turbo charger guard

8687 Mines RDM MNS/RDM/KZN/201920/013 for machine to prevent from fire incident.
Making a provision for safe walking on floor,

when drill power cable is laying in unsafe on
floor and get connected in to get & box for
8688 Mines RDM MNS/RDM/KZN/201920/005 power supply.
Making a provision for safe walking on floor,

when drill power cable is laying in unsafe on
floor and get connected in to get & box for
8689 Mines RDM MNS/RDM/KZN/201920/012 power supply.
ADM location need to be change to avoid

machine starting problem due to water
8692 Mines RDM MNS/RDM/KZN/201920/007 inserted it.
Making Machine reliable to diagnose the

problem easily and to avoid chances of
8693 Mines RDM MNS/RDM/KZN/201920/006 bypassing the fuses.
8695 Mines RDM MNS/RDM/KZN/201920/010 Positive locking of hanging part
8700 Mines RDM MNS/RDM/KZN/201920/009 Extra light arrangement in RBO
8710 Mines RDM MNS/RDM/KZN/201920/008 Pull out testing of new rock bolts.
8800 Mines RDM MNS/RDM/KZN/201920/011 Savings in ordering of VFD Panels
8967 Mines RDM MNS/RDM/KZN/201920/025 New led light provide at Tailing sump tank
8991 Mines RDM MNS/RDM/KZN/201920/024 Arrangement of stracher
Provision of Zabra crossing sinage at bus

8993 Mines RDM MNS/RDM/KZN/201920/023 stop in RD Mill
Provision for tail end side guarding in 1085
8997 Mines RDM MNS/RDM/KZN/201920/022 conveyor
Modification done in Ball mill motor cooling
9001 Mines RDM MNS/RDM/KZN/201920/021 fan net
Modification and replacement of reject

9006 Mines RDM MNS/RDM/KZN/201920/020 bunker chute
Introduction of bluetooth based handy

9009 Mines RDM MNS/RDM/KZN/201920/019 speaker for safety alert discussion
Introductsion of comapct size battery bank

9011 Mines RDM MNS/RDM/KZN/201920/018 for Fill Plant MCC
Modification in chemical pump guard such
9014 Mines RDM MNS/RDM/KZN/201920/017 that shaft covered
Modification in frame of contactor when P-
54 VFD contactor burnt out and spare not
9015 Mines RDM MNS/RDM/KZN/201920/016 one to one fixing
As camera adapter of weigh bridge was

getting burnt frequenlty whenevr rain
occures, Fixing the adapter in Ip protected
9038 Mines RDM MNS/RDM/KZN/201920/015 junction box
Team Leader Name No Of Team Member
Neha Jain (299390) 1
Kamlesh Bhandari (268169) 4
Pradeep Dhabaria (109118) 5
Sunil Sampla (278311) 3
Balmukund Rathore (311919) 4
Sanjay Kumar Barnwal (311993) 3
Sourav Dutta (288369) 1

Devkishan Sharma (561727) 2
Sujan Kothari (662587) 1
Alagu Ramkumar (573553) 2
Alagu Ramkumar (573553) 2
Roopesh Mehta (267584) 4
Omprakash Sharma (290991) 2
Sarth Bodawala (564892) 3
Yuvraj Rajput (277820) 2

Shashi Shukla (567721) 3
Rajulal Yadav (601030) 3
Manish Bansal (287014) 1
Nidhi Sharma (578943) 1
Sarth Bodawala (564892) 1
Vishvdeep Singh Rao (279860) 2

Pradeep Dhabaria (109118) 2
Rakesh Khurana (276643) 3
Yuvraj Singh (663243) 3
Sandeep Singh (299992) 2
Sandeep Singh (299992) 2
Ramji Lal Saini (312002) 1
Anup Kumar Das (568458) 1
Rajat Jain (581644) 2

Rajmal Mandowara (356819) 2
Shikhar Gupta (564902) 2
Harshit Srivastava (586582) 2
Rajmal Mandowara (356819) 2
Satish Thakare (564973) 2
Murali Bingi (296348) 2


Shashank Shekhar (568746) 2
Balmukund Rathore (311919) 2

Jai Prakash (581053) 2
Rajulal Yadav (601030) 1


Shashi Shukla (567721) 4

Ambareesh Jha (567802) 2
Neha Jain (299390) 1
Ramji Lal Saini (312002) 3


Problem Statement Why Why Analysis
1. For 2 material codes ARC was there but

amount in ARC got expired so putting ARC
PO was not possible. 2. Offer taken from the
ARC vendor. 3. it was found that for 2
material codes vendor has quoted different
rates than the ARC rates. 4. While going into
deep, we came to know that there are 2
While procurement of HP printer cartridge, types of packing size for the same type of
it was found that for 2 material codes cartridge one is single pack and other is dual
vendor has quoted different rates than the pack and the rates of dual pack is much
ARC rates. lower than taking 2 single cartridges.
ALIGNMENT OUT & BELT CONVEYOR SIDE
EDGE WEARED DUE TO CHENNEL WEARED
HEAD SNUB PULLEY WEARED LAGGING NOT THERE
G-80 flow was not sufficient As spillage is more.
For pump jam removal Pump is jammed
Pump break down frequently pump break downs frequently
Water control vales for cyclones provided at

better position for better control
MCC water pump needs to be started in

manual/MCC water pump starts in
automation with water level
No visibility for tailing lines leakage above

transformer area / Camera view given in
control room for all three tailing lines above
transformer area
SIPX Dozing jam frequently. SIPX sludge is forming

At reticulation bore hole drilling site there Less Illumination due to extended working
was very less illumination hours
Poor illumination after extended hours less illumination

Damage happening due to improper
Damage happening in gate end box mounting
No power at diesel pump and diesel stock
nil, mining operation hampered main cable got puncture at canteen area
While movement of crane no siren blows, no provision as craned are very old
Water accumulates in trench and due to

moisture to this mcc gets tripped as mcc is at lower height
Trolley Cable was damaging frequently at Due to blasting at crusher chamber, small
-35mRL Crane flying stone particles were damaging cable
Pull out testing machine had a limitation for

pull out the exposed rock bolt. It is designed
to test the rock bolts which is properly The machine was not designed for testing
grouted exposed rock bolts
Difficulty in identifying the length of grouted

rock bolt & thus to ascertain whether SSR
has been followed or not. To comply with the SSR norms & guidelines
1. cable getting damaged 2. due to blasting

EOT crain cable is frequently getting in crusher area 3. cable is in the zone of
damaged due to blasting getting hit by particle
Earlier required to shift density meters to

redundant line when it was in operation.
Now both tailing lines from tailing thickner
have own density meters for monitoring
density.
suction line jam as the drain valve muff not
Suction line jam while operating the pump properly operated.
Drilling water connection was only drawn

from 0 MRL to VRM section, incase of
stoppage of 0 MRL pump drilling water was Only drilling water Connection to VRM
not available In VRM Section Section
In running situation, machine lugs(+)(-) are

not covered properly even not insulated
properly which can lead electric shock when
machine is on mode..
poor visibility from operator comportment
at distance 25 metres Position of lights
Screen overflow & Chute jam issue
Isolator switch not working for ball mill -1

,due to this positive isolation not occur
Earlier ampere reading was not seen at
SCADA
Frequent burning of motor of P-7 water
recovery pump due to jamming
belt is stopped due to pull cord for taking
scrap
Time lapses in identification and inspection

of Hammer proper location of hammer is not available
Previously Metal hammer was used to hit on

inner tube to extract the core at each run,
due to this practice inner tube will get bend
and no useful for further operation.
jamming at 1085 discharge chute Gap between chute & pulley
MS LINE WORN OUT FREQUENTLY DUE TO MS BEND

TCS deposited for Royalty is not showing in Due to some error, TCS not shown in return
HZL 26 AS of DMG
Require detail deep drive on every element

of cost To present last 12 month trend of cost
Reserve station was not available at 125

mRL and thus there was a need for extra
development for the preparation of the Reserve station was not in present in
same 125mRL due to space constraint
Parking was done in an haphazard manner,
not much more smooth
Frequent failure of coolant hose and
twisting of Filter housing in MT 436 B Strength of mounting plate is low
DUE TO POSITION IT IS HIT BY BOULDER IN
FREQUENT DMAGE OF AUTOLUBE SYSTEM MUCKDRIVE
Rusting of floor, chemical hazard, poor
housekeeping
frequent damages of parking lights Light mounting are below the differential
There is no space for fast Less awarness of 5S and House keeping in
consumables,manuals & records manforce
Frequently damage by stone hitting position wrong
Two person is require for greasing Manual grease pump

Piston Rod & seal damaged by material
spilage on rod Piston rod are open
Wear out bucket pin and bushing dust enters in grease
Wear out bucket pin and bushing dust enters in grease
Rust on metal pipe due to water in UG
frequent failure of fan Excessive Vibration
Grade/Center line marking was in visible

due to erasing of paint used with jutes
Drill hole marking was disturbed due to
erase of color for marking Marking was disturbed
In ball mill no-4 low volume of water due to LESS PRESSURE REACHING TILL CYCLONES
this Cyclone pump sump jam AS PIPELINE WAS JAMMED
welding machine kept below Zn thickener

was frequently getting short
Frequent leakage of slurry pipeline. welding

or clamping takes time
Previously there was no arrangement for

wire prevention and wire got cut to loading
and unloading of goods.
Drill Jumbo was not able to pass from 100 Drill Jumbo not able to pass --> Height
mrl constraint
huge transformer oil leakage was from
transformer explosion vent bottom, neutral
bushing, conservator tank, and tap changer 1. oil leakage in transformer from many
which is causing regular top-up of places 2. gasket leakage. 3. gasket seal
transformer oil broken or bolt are not fully tight
shaft inset CCTV camera was limited to 1. shaft CCTV camera was limited to winder
winder operator, for monitoring any activity operator 2. it is an OFC cable network. 3.
going over there by section incharge was Auxiliary shaft is not connected by OFC to
not there main shaft. 4. Wi-Fi link is also not there
Pump available & not fitted Fittings are not available
Slower production Rate and shifting of

Shallow drive size in 100mRL of East lode Equipment was not possible
Ventilation problem in lower east lode

section No established Ventilation network
Non value added activities in RDM during
development cycle NVA Activities
To lay extra 500m HDPE Pipe resulting loss

of Man hours and NVA NA
No separate power connection for Jumbo Power cable cant be drawn in ramp due to
running in -65 MRL movement of LPDT
Bolt can rebound from jaw crusher, which

can hit the person in front of that
The Chemical area consists of MIBC storage

and handling which is highly flammable, The
present crane was having non flame proof
electrical panels and crane motors which Retrofitting of non flame proof crane with
are not safe as per the MIBC area. flame proof crane
As the ground level of fill plant transformer

is very low and when heavy rain occurs or
any line leakage occurs the transformer get
submerged and whole plant gets
breakdown. Low ground level of fill plant transformers
MT436B exhaust was directing towards side
wall in mine and thus lot of dust generating
and spreading across haul road. Done.
After steering hose failure direct oil splash

to engine causing equipment fire hazard. Done
FREQUENTLY DEVELOPING HOLE. IMACT OF MATERIAL

HEMM Environmental Waste transport was
being done in open body directly. Done
The machines were not on stand and while

hosing the water fall on its welding lead
connecting points Low height of machines
Telephone communication was not available

beyond 1900 Grid in NL & all major Adequate no of telephone and telephone
operations of Dev & production is running lines were not available to take extra
beyond 1900 Grid numbers
Radiator mask is not in proper position stand designed not available
Direction of LHD movement from Radiator

side no induction only light and back up alarm
there is always open pit behind the door of
container grating is movable
there is always 440 v supply in equipment Pilot ckt only cover 440 v which can be
after battery switch isolation isolated from equipment
while person working in ug workshop

,equipment take turn in workshop to
provide side to other machines no barricading at workshop
person not able to switch off the engine
while working on platform in emergency
case No switch available at platform
FREQUENT DMAGE OF HOSES AND WHILE LOADING WIRE MESS AND PIPE HIT
ELECTRICAL WIRING THE SYSTEM
Fan hub early play due to unavailability of
grease point Done
Due to 6 inch foot valve and pipeline

installed at the compressor house pumps, it
was becoming very difficult to remove the
pipeline for foot valve replacement. Weight of the valve and the pipeline.
NOT PROVIDING CONTINUOUS FILLING LOW DENSITY
Presently we there is no lead cell for display

of load being lifted by EOT cranes of mill and new installation for safety and better
surface monitoring
Present there is no indication/alarm when

by mistake the dump body remain in up
position, this mat create a incident of
collision with overhead lines/pipe rakes(as NO indication available for dump box
happened in Zawar recently). position
Old Panel were not having gate and water

and dust gets ingress creating more
maintenance and breakdown of crane. The
safety was also issue as panel were having To replace the panels with new panels
openings having proper IP protected doors
Old hooks were not having latch facility as

they were in operation since inception and
earlier no provision available. So to meet
the crane safety guidelines we have
replaced the hooks with wire rope for
enhancing the crane safety and comply the In old hooks no latch fixing facility available
requirement and also hooks and wire rope was damaged
Old LRS was leaking and welding not

possible on body as it was corroded, also
the LRS was conventional type and now a
days Vapromatic type LRS are coming which
have better safety and reliability Old technology and less reliability and safety
Presently operator reported that while
moving towards the tailing battery and
mixing tanks they observed less illumination
and there is chance of slip as slurry spillage less illumination near valves of tailing
being available near r the valaves battery and mixing tanks
The light installed in grease and lubricant

room is not flame and is a safety threat as non flame proof light available in grease and
can be a factor for fire lubricant room
Operator not aware for tank empty, causing
crusher jam Display not available in control room
Structure is week Rusted & corroded
Manual lock is slipping Spring is not there

STONES ARE LAYING BETWEEN PULLEY &
CHUTE CHUTE DESIGN PROBLEM
Anything fall from 1085 conveyor No deck plate
No railing & toe guard Require for Safety
LADDER UNSAFE DESIGN TO BE MODIFY
It was unsafe to drain and area was spilling Area was getting slippery
The stand by zinc conc recirculation pump Leakage in the tech taylor valve, Sharp bend
was jamming frequently due to leakage in in common delivery line due to space
tech taylor valve. constraint.
Crusher crane current caring wheel wear so

supply wire frequently derail from wheel Supply carrying conductor derail from wheel
due to sudden jerk so crane tripped & not start
Improper delivery of lubrication compound.

High Vibration in Ball mill 2 NDE plummer Compound was getting discharged at one
block. side of girth gear.
Frequent leakage of MS feed nipple Tailing slurry wears out MS piping

In ckt -4 cleaner distribution box was over Over flowing of slurry due to slurry
flowing and spilling. deposition.
Belt conveyor 1085 to stop at proper Belt conveyor stop by operator from pull
position when magnet sensor alarm come card so belt stop far from position .
As per conveyor safety standard conveyor Old pull card switch provide at conveyor
guard provide along the belt so pull card not supporting frame & conveyor seal from
operate by person due to guard above pull guard so switch not operate by any person
card switch. due to inside
MCC gate is open inside so as per safety law

it should be open out side & gate must be Old gates not as per safety HZL safety
anti panic standards
If incident occur in cyanide area no
No Hooter alarm in sodium cyanide communication for calling
When sonolied valve operate from cycle for

No auto drainer system in compress air draining the water air was wastage with
storage tank water so energy loss in form of air
IN ISA control room AC out door unit was

installed at 4 mtr height from ground level Out door unit to be shift at ground floor
so it is unsafe for maintance of out door unit plate from
ARC flash dress kept in open so dust deposit
on dress & worn Dress to be kept in close glass Almira
Rescue hook to be kept with clamp in
No proper position of rescue hook in MCC approach area
Three phase supply given to drill m/c at

Drill m/c supply not having ELR system MCC from DOL feeder
Smoke deductor system not available in

No smoke deductor in MCC MCC if fire occur in electrical panel
LED light to be provide in pump area in
Low lux level in vacuum pump area place of HPMV light
Old wooden stand for battery bank was
damage due to wood damage from acid New RCC stand to be made
There were many joints for connection of

ball mill 4 pedestal fan and switch boards at
mill area the joints were unsafe
poor welding joint ,increase Hazard need some insulated joint

GET LIP plate of LH 410 crack ,lip not
available Lead time is to high
person working in line of fire as boom support available is low in height
PHC4 machine was tripping continuously

due to overheating and temperature was Why-why analysis done and found that
going beyond 72 degree centigrade. cooling efficiency of system is not adequate.
: Exploration drilling Machine U4 had got

over heating problems since many days Overeating issue
In this situation ,there was no any

arrangement to keep compressed cylinder
in safe manner in under ground garage and
there is risk of fall which may lead any
incident. Done
In this situation ,there was turbo charger

guard missing which acts as a heat shield
and there is risk of fire in machine which
may lead any incident. Done
In this situation ,when drill power cable is

laying on floor in unsafe manner and
connected in to get & box, for power
supply.then there is a chance, during
walking person leg's get touch with power
cable and may be dis balance and falls on
floor. Done
In this situation, metal plate as a joiner were

using and connect the welding holder lead
through nut & bolt. So there is high risk of
electrocution as well as fire risk Done
In this situation, ADM kept side of the

hydraulic hoses below AC box and due to
moisture and during washing water content
enters in it and makes it hang which lead to
stating problem. Previous location Of ADM
was located Done
In this situation, if 10 Amps fuse got blown

which is situated on ECM, it will be time
taking to replace and rectify the problem.
Here fuse is used for powering the ECM and
used as safety device for ECM. Done
The sudden fall of the scissor frame, in-case
loss of hydraulic pressure in the hydraulic
cylinder Done
Low visibility in U/G during machine
operation Done
We changed our rock bolts to bolt dia of 42

mm but earlier it was 36mm so we had no
setup to do the pull out test, which is a
statutory requirement. Done
M/s Samhita is the only authorized dealer of

ABB. We always take ABB VFD modules from
The vendor has quoted random initial prices this vendor only. We give focus on VFD
of VFD panels module and other high-value items.
presently no proper light provide on tank to
watch the sump level additional light to be provide
Presently no proper facility for shift the If any person slip in field & not move self
injured/ sick person from work site to safe than person wait for ambulance for first aid
palace in safe area
At Mill entrance many vehicle enter in mill

from main road & also bus park at same
Presently bus stop at the enter of mill area place due to drop & pick up of employee
& no signage for parking after duty
No provision for tail end side guarding in provide a new guarding at tail side of
conveyor belt conveyor
Abnormal sound coming in motor due to its new thread to be made/ locking
DE side fan cover bolt thread slip arrangement to be done
Existing bunker was not functioning well and

its structure was fully corroded Old design
As plant noise is there so when alerts being

discussed the voice of safety officer was not No speaker available for addressing mass
audible to all persons people to discuss safety alert
Old battery bank was fully damaged and

leaking also the size of stand was more and
problem comes while doing PMI Old design battery bank and problem in PMI
Shaft was exposed and guarding was Shaft guard not provided by pump
inadequate manufacturer
Spare contactor of one one size not viable
and P-54 urgently require to start spare not one to one fixing
Frequent burning of camera adapter Adapter was covered by only polythene

Root Cause Idea
The LI which have dual pack size identified

(confirmed for deletion), extended for RD
1. Material code not present in all plant mines plant code and the new PR made
code. 2. Less awareness about the packing with material code having dual pack in
size and the profit related to this. description.
CHANNEL WEARED RUBBER LINER FITTED
LAGGING NOT REPLACED TIMELY REPLACE PULLEY

G-80 modified with G-100 casing and
As spillage is more. impeller.
We have used 3/4 inch pipe for jam
Time taken for jam removal is high. removal.
pump running empty Level sensor fitted
Position of the valve was at such a point Valve can be fixed at position which is easily
that person had to go to FST to control it approachable for operator
MCC water pump starts in automation
Camera to be installed in the transformer

No immediate information for any line area crossing lines & view to be given in
leakage in fill plant control room control room
SIPX Dozing pump and reagent line jam To use a spare tank for dozing
absence of high efficient lights Install high efficient LED lights
Poor illumination after extended hours New LED lights to be installed
Improper mounting Proper mounting and hanging to be done

arrangement of new source for diesel pump
cable puncture for providing power to diesel pump
installation of siren by modifying the crane
no siren on crane circuit.
installation of tullu pump in trench with

water accumulation in cable trench level sensor controlled
Due to blasting at crusher chamber, small

flying stone particles were damaging cable Damage prevention of Trolley Cable
The bridge assembly was extended by in

house welding & use of a bigger cylindrical
pipe so that it can be fitted to exposed rock
bolt & start the pull out test of those
Design Competency Issue exposed rock bolts
Different colour coding of 1.8 m & 2.4 m

rock bolting with an identification mark
Difficulties in identifying the length of painted in yellow for 1.8 m & red for 2.4 m
grouted rock bolt at the tip of the rock bolt
cable is in the zone of getting hit by the to reroute the cable in such a way it is being
particle during blasting protected by the particle
Process improvement and safety of

equipment .
Drain valve removed and 3 inch socket and
Suction line jam plug fitted
To install a alternate drilling water

connection for VRM section from Surface to
No alternate means of water connection for have continuous water supply incase of
Shut down of Pumps Pump Maintenance in 0MRL
Machine have not provision to cover this Cover both the point such that no external
lugs. object hit the lug
Height of light position to be improve Height is increased
Screen where Out of view of operator for Monitoring to be done from control cabin
process handling room
Isolator pin sheared Repair/ replace the isolator pin
required for jam condition and tripping ampere observation was required for motor
Thermal relay taking mare time to trip Thermal relay replaced by electronic relay
Local control stop switch to be provided
Belt don't stop at proper place near operator desk
hammers are not been tracked fixing of stand for Hammer
Plastic hammer is now used rather than

metal hammer
More gap Gap between chute & pulley Reduce the gap or modify the chute
MOC NOT GOOD CHANGE THE MOC OF PIPE

For taking benefit of Advance deposit of Tax
Timely updation of Qtrly Return setoff by TCS
Yes, Make detail on 40 slide ppt which

include scrap, norm, COP and Inventory
trends Make HZL wise same format
To develop a reserve station in 125mRL in

Space constraint in 125 mRL the unused X Cut
To stick the reflector strip on surface
Thickness of mounting plate is low Change in thickness and mounting bolt

NEED TO PROTECT OR CHANGE THE
POSITION PROVIDE IT WITH GUARD
spillage of chemical hence corrosion coating with Pidilite floor fill
Rear Parking light mounting modification.
Reshuffling of oil room and container
broken by hitting stone MU antena position change in new ST1030
Two person is require for greasing

MT436B -03 Steering cylinder rod covered
design problem by conveyor belt.
dust seal not available Dust seal fitted in Bucket pin ST1030 -06
dust seal not available Wear out bucket pin and bushing
Painting Done in Brake metal pipe MT436B-
anti rust Painting is require 02
no mounting on upper side of radiator Radiator mounting modification in ST 7
Paint with jutes being used for marking To mark the faces using the spray paints
To use steel peg with the color for marking
Paints used for marking was erased of production drill holes
Cyclone water line reroute in ball mill feed

Cyclone water line jam chute
Water splash on the connectors due to

frequent cleaning of concentrate in the area
thickness of pipe reduced due to wear,

makes it hard to weld. clamping not possible Use of wrap seal which seals the leak with
near flanges. putty and covers the area with hard coating.
Manage the height of drill jumbo by

Less height of existing drive in 100mRL alternate tire size
to arrest the oil leakage by putting the metal
adhesive putty in the area identified to stop
gasket seal broken the leakage
auxiliary shaft is not connected to main to create a Wi-Fi network send the camera
shaft neither by OFC nor by wi-fi signal on mobile phone
Fittings are not available Make new one & modify the fittings
Shallow drive size causing slower production Stripping of 350m in 100mRL Main drive to
Rate facilitate more space in the drive
Installation of Booster Fan in 50mRL East

lode on top of 50 to -87mRL raise to
establish ventilation network resulting flow
No established Ventilation network rate upto 20 Cum/Sec
Attached in the doc Elimination and reduction of NVA
To drill a borehole from 195mRL to 180mRL

and thus used existing pipe of 195 MRL for
Filling in stope 351N-180mRL filling purpose
Power cable cant be drawn in ramp due to Erecting power cable through borehole from
movement of LPDT -65mRL to -87 MRL
To protect the plate in front of plate To install plate in front of the bolt
Unsafe crane and panels Safety improvement
To remove the settled slurry/mud and do

the civil PCC of area making the area fully
Low ground level of fill plant transformers dry during rainy season and any leakages
LPDT exhaust was directing towards side
wall and thus generating dust. Changing direction of exhaust.
Partition is to be provided in between

Engine is directly exposed to steering pumps engine and steering pump system to avoid
system. direct splash to engine.
INHOUSE 20MM PLATE PANEL
FIRST PANEL REQUIRE MORE THICHKNESS REPLACEMENT
To properly pack all waste material and than
Yes transport.
to shift on stand of approx. 6 inch to save

low height water ingress in it
Adequate no of telephone and telephone

lines were not available to take extra Re-use & diversion of existing extra nos at
numbers HEMM Junctions to UG
Stand not available Stand to be fabricated for safely
different light can be used Installation of green light
need to fix grating weld the grating at blind end of door
need to design ckt to check input voltage to

Ckt is not deigned in such manner zero
barricading to be provided so person can

work in safe zone if hemm take turn at
workshop chain barricading to be done
emergency switch to be provided at
control to be provided at lift platform
NEED TO PROVIDE GUARD FOLDABLE GUARD TO BE FITTED
Done Grease point provided in fan hub
Heavier weight was resulting in inability to Replacing the 6 inch foot valve to 4 inch foot
handle it properly. valve by providing a reducer nipple.
NO EXTRA LINE AVAILABLE EXTRA LINE TO BE PROVIDE
Installation of load cell in Mill EOT cranes for

old cranes do not have load cells display of Load being lifted by crane
Installation of proximity switch for providing

Dumper dump body positioning status in
siren to be given in driver cabin for alertness driver cabin by siren to enhance safety
Electrical damaged Panel replacement of 5

Damaged panels ton MCC side Crane
Replacement of 5 Ton MCC side and 5 Ton

Filter side crane lifting hook and wire rope
to enhance safety as latch were not
hooks and wire rope to be replaced available in old look
Replacement of OLD ball Mill 3 conventional

to be replaced by Vapromatic type , this type LRS by Vapromatic type LRS to save
type being first time used in HZL water leakage and enhance safety
Illumination improvement near Tailing
battery and cement mixing tanks to enhance
less illumination at working area safety while opening the manual valve
Installation of flame proof loght in grease

non flame proof light and lubricant room
Oil level indication to be provide New level sensor with indicator to be fitted
Require Strengthen Re strengthen the existing structure
Spring to be fitted New modify spring fitted
CHUTE DESIGN TO BE CHANGE CHUTE TO BE MODIFY
Deck plate Require New deck plate Fixed
Railing & toe guard require Railing & toe guard to be fixed
LADDER TO BE MODIFY LADDER REPAIRED
To change the direction on opposite side Drain plug direction changed
To place a separate line for both the pump.

1.Leakage in the tech taylor valve 2. Sharp Separate HDPE line laid for 7300 pump and
bend in common delivery line due to space existing line connected with 7719 after
constraint replacing the TT valve and bend.
Damage brass stud to be fill from brazing &

Wheel fixing stud damage due to sparking machining to be on stud & New bush to be
between wheel & stud as a gap increase & provide in brass wheel as per stud size so
wheel center is oval so during sudden brake clearance between stud & wheel become
of Long travel its wheel derail from wire so zero & wheel no tilt during sudden brake in
crane motor tripped on singl long travel .
Compound delivery header was displaced We made an arrangement to restrict

from its mean position. header's too and fro motion.
Tailing slurry wears out MS piping Replace feed nipple with HDPE spool piece
Box size was small. Slurry deposition was
more. Box height to be increased.
Belt stop far from position so conveyor take provide stop push button near operator so
more time to restart & production affected when alarm come immediate stop the belt
also some time iron piece go in crusher so by person & remove the foreign material
equipment may be damage. quickly
Shift all pull card switch above guard & re

Pull card switch location to be change routing the cable
Provide new aluminum gate which is open

out side Replacements of MCC gates
No hooter alarm to calling for help Provide a hooter in open area
No auto drainer system to reduce frequent

draining of water Provide auto drainer in storage tank
One stand made above one meter height

Out door unit to be shift at below area from ground & out door kept on this
Dress to be kept with hanger in hanging Procure the long Almira with front clean
position glass
New lamp to be made for rescue hook & clamp to mount on wall near approach area
discharge rod & kept in clamp
Provide the ELR system in DOL supply &

No provision of ELR in drill M/C tripping contact to be taken from ELR relay
Smoke /fire system to be provide at MCC & Provide smoke deductor & its alarm to be
chemical area where MIBC is used provide in control room
165 watt LED light to provide in place of 400
Low lux of HPMV light watt HPMV light
New stand to be made New RCC stand to be made
providing junction box with RCCB for power

supply and laying new armour cable for
more joints switch boards
joint not explore Joint to be explore
Lip failed from side Development of LIP

as boom stand height is low for regular use Need to have stand for working
Higher capacity of cooler is to be fixed in

Cooler efficiency required to be improved. system.
Replacement of existed Air cooler with

Jumbo machine Air cooler to control
Air cooler not functioning properly Hydraulic oil temperature
Sandvik team modify the safe & secure

Proper arrangement was not available at UG stand at HEMM workshop and shifted to
workshop for eliminating this type of risk. under ground garage.
Sandvik team modify the safe & secure

Spare was not available. guard at HEMM workshop .
There is no any cable routing arrangement Sandvik team modify this cover in house &
given to near get & box for power supply place it near GET & BOX.
There was no any provision given for

connect the welding holder at UG
workshop. After that we arranged the male
& female coupler along with aluminium lugs We modified the get end box and fixed at
and fixed in to plastic box, so welder can ea Sandvik UG workshop.
There was always starting problem due to

ADM not responding as it gets wet due to
water or hydraulic. Now it has kept in the
cabin behind the display by extending the We modified the harness & location of
wires. It will make machine mor ADM.
After modify the connector X3221 by

putting the 10 Amps MCB in front box ,
giving power to engine in case of tripping or
overcurrent easy to rectify and checking. We modified the get end box and fixed at
This will make no go chance for by Sandvik UG workshop.
No positive locking for that part provided Positive locking on multi mac
Low Visibility Fix Extra light
We have to procure new setup to do the

testing that would take time,so we modified We modified the old setup to carryout pull
our current setup by making some out testing of new and old rock bolts from
dimensional changes in the same setup. the same setup
We have placed 2 VFD panels order from

Dec'18 to Mar'19 so the BOM of present
We give focus on VFD module and other requirement can be compared with previous
high-value items. 2 BOMs.
New flame & dust proof LED light to be
provide on tank for watching the level
one starchier is kept in control room for

No provision of starchier emergency
Parking area to be shift from mill entrance &

No zebra signage on main Road zebra signage to be provide on main road
Clean the tail end area of conveyor Guarding Fabricated new guard at tail end for 360
to be done degree protection
Locking arrangement to be provide one clamp to weld & lock the fan cover
In house fabrication of New chute bunker

Inefficient chute bunker and installation
Introduction of Bluetooth based handy

portable Speaker not available speaker for safety alert discussion
New Fully compactable type bank mounted

Size was more and stand was not ok. Also in stand to be installed with SS links of
links were damaged battery
For covering the shaft mesh to be installed
manufacturer not provided the shaft gaurd for ensuring the guarding
Change in frame by drilling the new holes
unIdentical spare available and fix as per old bus bar dimesion
Fixing the adapter in Ip protected junction

water ingress of rain box
Result Achieved Counter Measure
For the particular PR by changing the

material code, there is a savings of INR Such type of material codes to be identified
49,605. and awareness to be given to the user.
STOP DAMAGE OF CONVEYOR OTHER AREAS
REPLACED 2-3 EARLY PLANT RUN IN B SHIFT
Spillage was not accumulated. Flow increased
It take less time for pump jam removal Time taken 15min initially it takes 1/2 hour.
Pump Performance increased operation hours minimised
New valve provided near P-47 pump from

where cyclone water can be controlled Water control become easy & extra water
easily injection to FST reduced
MCC water level always remains in control if No plant tripping due to fill plant MCC due
water enters the plant to water issues.
All three lines area clearly visible from All leakages immediately being captured
control room screen from control room itself without any delay.
Production not effected Production

Extra LED lights procured and regular
Improved illumination update to UG Electrical department
Improved illumination 3no LED lights provided

Chain welded to all gate end box and bolted
Less damage occurring in rock bolt
power given and started diesel pump cable joint to be made on cable coming
started from dg set
siren installed and it blows to alert person siren installation on crane for alertness to
working in the area persons working in the area
dry cable trench installation of tullu pump
Trolley Cable rerouting done and laid in

no damage till now in cable platform. mounting arrangement done.
Pull out test of exposed rock bolt

successfully done. The existing machine was
full utilized & enabling not to order a
specific machine for exposed rock bolt &
thus saving cost of a new machine which Extension of bridge assembly & use of
was to be procured bigger cylindrical pipe
Easy in differentiation in a particular face

even after the grouting
breakdown due to cable damage has been

reduced to zero
Process improvement .
suction line not jamming suction line not jamming.
Alternate water connection from the surface

line has been erected so to have continuous Alternate water connection with surface
water availability in VRM Section water line
Done
Checked visibility of operator is not
Range is changed from 25 mtrs to 30 mtrs disturbed .
1.Fast actionable from operator in overflow

and jamming. 2. Safety of chute from jam
and overflow avoiding. which enhances
running hours .
After fitting new pin , isolator switch work Now positive isolation is occurring
1. amperage reading available for record
and tripping
burning of motor of P-7 water recovery
pump is 0 Motor changing is zero
Belt stopped at proper position
Fixing of hammer at its position ,hammer

Easily traceable hammers , identification , stand made in such way that hammer are to
storage ,inspection be kept at its position only
Financial benefit achieved Plastic hammer used
Reduce the gap Less jamming
BALLOW HOSE REPLACED NO LEKAGE

Updation of TCS of Rs 13.26 Crores for RDM Updation of TCS amount, Working capital
in HZL 26AS reduction
Sep-18 BMG presentation made in same

fashion Timely reporting of information
Reserve station developed in 125 mRL Development of reserve station in 125mRL
Smooth parking achieved

change of size of plate and mounting bolt
No failure after modification strength
ZERO DAMGE TO SYSTEM PROVIDED WITH 12 MM PLATE

No accumulation of spillage, fast cleaning of
the floor NA
done 03 TRUCKS
Done in all new ST1030
Done in all new ST1030
only one person is require for greasing
Done 03 MT436B
AWAITED
AWAITED
Completed
successful working
Grade & center line is now clearly indicated
Implemented in -23mRL P5 stope
Now water volume was sufficient & sump Cyclone water line reroute in ball mill feed
jam not occur chute. Now water addition in control
Fast leakage arresting and good reliability
Drill Jumbo crossed the constraint area

without damage NA
complete oil leakage has been arrested regular monitoring
successfully taken the camera monitoring on

mobile phone
Centrifuge installed Oil filtration started
260 m of Stripping has been completed
Fan installation successful and air current is Installation of Booster Fan in 50mRL East
24 Cum/sec lode on top of 50 to -87mRL
Improvement actions identified and in
progress
Filling completed in a shortest time & no To drill a borehole from 195mRL to 180mRL
additional manpower was required and and thus used existing pipe of 195 MRL for
HDPE pipe of 500m length was saved filling purpose
Erecting power cable through borehole from

Commissioning of Jumbo-3rd Dec -65mRL to -87 MRL
Safety achieved MS plate installed
Retrofitting of non flame proof crane y

Safety and reliability flame proof
Civil PCC the area and install the tullu pump

During heavy rain the transformers do not with level sensor to immediately remove the
got submerged/tripped accumulated water.
Exhaust diverted towards back side and thus
less dust generation. Exhaust modified.
Oil is not coming directly to engine and

hazard of equipment fire eliminated.
OK LIFE OF FIRST PANEL
Yes PP Bags started using for waste collection.
machines shifted and water while hosing

will not ingress
1.Use of Old line to transfer numbers into

UG & laying of new 20 pair cable from
HEMM junction box to shaft inset 2. Taking
of these extra numbers to 250 mRL inset 3.
Laying of new cable from 250 mRL inset to
1900 Grid & distribution to 300, 269,285,
236 mRL with new telephone cables 4.
Fixing of IP65 weather proof telephone
5 New numbers been given in NL handset at all levels of NL
safe and proper stand no wooden support
When machine move in front away from

person green light will work ,allow person to
move in direction .when machine move in
backside it become complete red stop
person to move in direction To be checked in maintenance
grating is fixed at door step need to check for grating always
achieved implementation of new pilot ckt
person working inside the chain new passing bay to be create

able to switch off engine from platform in
case of emergency need to check ckt in fix interval
ZERO DAMAGE AFTER FITMENT --
Yes --
Now it became very easy to handle and

maintain the foot valve , as 4 inch foot valve
is a standard valve present at the mine.
CONTINUOUS FILLING PROVIDED FII RUNNINH HR TO BE INCREASE
installation of load cell completed NA
Installed on reject handling dumper NA
New panel for MCC side 5 ton crane

installed and checked running success fully NA
hooks and wire rope replaced NA
LRS replaced NA
Illumination improved and better working
atmosphere NA
Installation of flame proof light in in grease

and lubricant room done NA
Oil display visible to operator desk. display is showing
ok having higher strength
ok Not slipping
DONE NO JAMMING
Ok ok
done ok
OK OK
Area became safe to work Area clean
No jamming and leakage from the pump
After modify in wheel & stud crane running Current carrying wheel new brass bush fixed
smoothly from last 15 days without tripped as per stud size .
Uniform greasing throughout the girth gear

and hence reduced vibration in plummer
block.
No leakage in last 2 months
NO spillage No leakage
After provision of emergency stop belt stop Restart time reduce after magnet alarm &
near field operator production increase
New switch provide above guard post &

cable rerouting done New pull card with indication provide
MCC gate replace which is open out side NA
Now hooter in working in emergency NA
Now when drainer is full from water than

valve operate & no wastage of air frequently NA
stand made & shift out door unit now work

at height job eliminated NA
All type of dress ( 100k , 40k , 8 K ) is kept in
glass Almira NA
both rod fixed in clap with tagging NA
New wiring done & tripping taken in line NA
Smoke deductor sensor provide in MCC &

chemical area its control panel & hooter
provide at control room. All MCC of mill area
Lux improve from 36 to 127 NA

New RCC plate form was very safe for
maintance work NA
electrical safety enhancement of mill area NA
zero cable joint need to check periodically
LIP received Checking as per Stand

no work under machine use as per requirement
Temperature difference increased from 8

degree to 14 degree. Higher capacity of cooler installed in system
drilling increased replacement of cooler
Falling risk eliminated. Modify the safe & secure stand
Fire risk eliminated. Modify the safe & secure guard
1. Slip/trip risk eliminated. 2. 5'S

improvement. Modify this cover in house
Modified the get end box and fixed at

Electrocution & fire risk eliminated. Sandvik UG
It will make machine more productive. Modified the harness & location of ADM
1. The modified circuit will make the

machine reliable by making easy to trace
the problem and rectify. 2. This will make no
go chance for bypassing the fuse as fuse will Making easy to trace the problem and
be eliminated from the circuit. rectify
Positive locking system prevents the sudden
fall of the scissor frame, in-case loss of
hydraulic pressure in the hydraulic cylinder --
Improved Visibility Fix extra light
The change in setup will help us meet the

statutory requirement for pull testing.(10 % Modified current setup by making some
of installed rock bolts to be tested). dimensional changes in the same setup.
After comparing the BOM and negotiating

with the vendor 33% savings achieved from Panels BOM to be compared before
the initial quoted price. negotiating with the vendor.
Light provide at sump tank so better level to
be measure
Procure fordable starchier & kept in each

control room
Bus parking area shift from mill entrance

gate to avoid incident
360 degree guarding done in conveyor belt
Abnormal sound stopped
better efficiency of chute with minimal

spillage NA
better communication between workforce

while alert discussion NA
in less area installed and easy ness in

checking the voltage and easy PMI NA
Guarding of shaft done and safety increased
up NA
P-54 panel made ready for operation NA
stoppage of burning of camera adapter NA

Scope for Horizontal Deployment Registration Date Kaizen Initiated Kaizen Completed
In all location and to the persons who make

PR of cartridges. 17-May-18 11-May-18 17-May-18
ALL OTHER AREAS 10-Jul-18 28-Jun-18 28-Jun-18
OTHER AREAS 10-Jul-18 4-Jul-18 4-Jul-18
In pump area 18-Jul-18 18-Jul-18 18-Jul-18
Other pumps 18-Jul-18 13-Jul-18 13-Jul-18
Dewatering areas 24-Jul-18 21-Jul-18 22-Jul-18
NA 24-Jul-18 2-Jun-18 6-Jun-18
NA 24-Jul-18 19-Jun-18 23-Jun-18
NA 24-Jul-18 14-Jul-18 17-Jul-18
For another reagents. 24-Jul-18 18-Jul-18 19-Jul-18
Less illuminated sites 26-Jul-18 26-Jul-18 26-Jul-18
Any area with less illumination 26-Jul-18 24-Jul-18 24-Jul-18
All gate end box 26-Jul-18 10-Jun-18 10-Jul-18

NA 27-Jul-18 13-Jul-18 13-Jul-18
on other cranes 27-Jul-18 18-Jul-18 18-Jul-18
na 27-Jul-18 2-Jul-18 2-Jul-18
Any Crane with such problem 1-Aug-18 15-Jul-18 22-Jul-18
Can be deployed in all the units of HZL &

other UG Mines across Vedanta 7-Aug-18 25-Jul-18 30-Jul-18
Can be deployed in any UG Mines across

Vedanta 7-Aug-18 13-Jun-18 28-Jul-18
NA 18-Aug-18 1-Aug-18 4-Aug-18
Already have density in both lines. 20-Aug-18 14-Aug-18 17-Aug-18
P-53 pump 23-Aug-18 3-Aug-18 3-Aug-18
All UG Mines Across Vedanta 27-Aug-18 21-Aug-18 24-Aug-18
Across HZL welding equipment 9-Sep-18 2-Sep-18 2-Sep-18

Yes 17-Sep-18 10-Sep-18 10-Sep-18
Can be done for other conveyor chute. 17-Sep-18 11-Sep-18 11-Sep-18
Ball Mill-3 17-Sep-18 6-Sep-18 6-Sep-18
Already done for other motor 17-Sep-18 7-Sep-18 7-Sep-18
All dewatering pumps 17-Sep-18 3-Sep-18 3-Sep-18
Every conveyor where magnet is placed 17-Sep-18 6-Sep-18 6-Sep-18
at all hemm 19-Sep-18 17-Sep-18 19-Sep-18
In each mine 22-Sep-18 17-Sep-18 21-Sep-18
All other discharge chute 24-Sep-18 19-Sep-18 19-Sep-18
IN ALL OTHER CIRCUIT 24-Sep-18 6-Sep-18 6-Sep-18
Continuous updation for next period 26-Sep-18 1-Jun-18 28-Aug-18
Another cost elements 26-Sep-18 1-Sep-18 6-Sep-18
Applicable to all UG Mines across Vedanta 27-Sep-18 26-Sep-18 26-Sep-18
All mines 28-Sep-18 20-Aug-18 23-Aug-18
All MT436 B with Cummins engine 28-Sep-18 12-Aug-18 12-Aug-18
IN ALL NEW st1030 28-Sep-18 19-Jul-18 19-Jul-18

Oil room 28-Sep-18 15-Sep-18 20-Sep-18
All Mines across HZL 28-Sep-18 18-Jul-18 19-Jul-18
All the Mines Across HZL 28-Sep-18 20-Aug-18 1-Sep-18
All the Mines Across HZL 28-Sep-18 25-Jul-18 25-Jul-18
All the Mines across HZL 28-Sep-18 25-Aug-18 25-Aug-18
All Mines across HZL 28-Sep-18 26-Sep-18 26-Sep-18
All the Mines across HZL 28-Sep-18 27-Sep-18 28-Sep-18
All the Mines across HZL 28-Sep-18 12-Aug-18 12-Aug-18
All the Mines across HZL 29-Sep-18 1-Aug-18 27-Sep-18
All the UG mines across Vedanta 29-Sep-18 22-Aug-18 26-Sep-18
NO 29-Sep-18 5-Sep-18 15-Sep-18
Welding machine at flotation 30-Sep-18 1-Sep-18 5-Sep-18
All slurry pipelines 30-Sep-18 1-Sep-18 3-Sep-18
yes 4-Oct-18 4-Oct-18 4-Oct-18
Depend up on particular case 25-Oct-18 2-Sep-18 4-Sep-18

may be applied very similar leakage in oil
from transformer 26-Oct-18 18-Oct-18 21-Oct-18
may be used as per requirement 26-Oct-18 1-Oct-18 10-Oct-18
In all Crusher 28-Oct-18 15-Oct-18 15-Oct-18
All the Shallow drives in UG Mines across

Vedanta 20-Nov-18 25-Sep-18 4-Oct-18
All the UG Mines in Vedanta 20-Nov-18 17-Oct-18 23-Oct-18
All the Mines of HZL 23-Nov-18 17-Aug-18 22-Nov-18
All the Mines of HZL 24-Nov-18 10-Nov-18 24-Nov-18
All the Mines Across HZL 5-Dec-18 20-Nov-18 3-Dec-18
All MINES 12-Dec-18 9-Dec-18 11-Dec-18
SKM reagent area 24-Dec-18 15-Dec-18 18-Dec-18
NA 24-Dec-18 17-Dec-18 24-Dec-18

Can be implemented in same model at
other mine site. 4-Jan-19 7-Sep-18 20-Nov-18
Can be implemented in other MT436. 4-Jan-19 20-Dec-18 22-Dec-18
OTHER SCREEN 7-Jan-19 20-Dec-18 20-Dec-18
Yes. 19-Jan-19 14-Jan-19 17-Jan-19
all areas of mill 22-Jan-19 21-Jan-19 22-Jan-19
South _East Lode 28-Jan-19 1-Jan-19 20-Jan-19
For all radiator mask 29-Jan-19 27-Jan-19 28-Jan-19
in all LHD /LPDT 29-Jan-19 18-Jan-19 19-Jan-19
no 29-Jan-19 20-Jan-19 20-Jan-19
all jumbo across HZL 29-Jan-19 8-Jan-19 9-Jan-19
all such location 29-Jan-19 21-Jan-19 21-Jan-19

in all multimech 30-Jan-19 8-Jan-19 9-Jan-19
IN ALL SL 30-Jan-19 17-Jan-19 18-Jan-19
Yes 30-Jan-19 28-Jan-19 29-Jan-19
at the 100 North Pump House 31-Jan-19 8-Jan-19 15-Jan-19
NA 10-Feb-19 4-Feb-19 6-Feb-19
All Mill EOT cranes already covered 18-Feb-19 1-Jan-19 17-Feb-19
All Mill Dumpers 18-Feb-19 14-Feb-19 15-Feb-19
Filter side 5 ton crane 18-Feb-19 1-Dec-18 1-Feb-19
NA 18-Feb-19 1-Dec-18 10-Jan-19
Ball Mill 2 & 1 18-Feb-19 15-Dec-18 16-Dec-18

NA 18-Feb-19 7-Feb-19 10-Feb-19
all flammable liquid rooms/area 18-Feb-19 10-Feb-19 11-Feb-19
ok 19-Feb-19 8-Feb-19 8-Feb-19
Other structure 19-Feb-19 1-Feb-19 5-Feb-19
Other crushers 19-Feb-19 11-Feb-19 11-Feb-19
OTHER CHUTES 24-Feb-19 22-Feb-19 22-Feb-19
In Other Conveyors 24-Feb-19 19-Feb-19 19-Feb-19
In Other areas 24-Feb-19 20-Feb-19 20-Feb-19
IN OTHER AREAS 24-Feb-19 21-Feb-19 21-Feb-19
in other mixing tank 8-Mar-19 1-Mar-19 1-Mar-19
NA 8-Mar-19 20-Feb-19 21-Feb-19
All Without DSL system crane . 9-Mar-19 22-Feb-19 23-Feb-19
Ball mill 1,3,4 9-Mar-19 8-Mar-19 8-Mar-19
None 9-Mar-19 1-Feb-19 5-Feb-19
In other distribution box 11-Mar-19 1-Mar-19 2-Mar-19

where metallic sensor installed in belt
conveyor 13-Mar-19 22-Nov-18 22-Nov-18
All conveyor in mill area 13-Mar-19 14-Dec-18 14-Dec-18
DG set MCC 13-Mar-19 12-Oct-18 13-Oct-18

Remote critical area where person not
available 14-Mar-19 16-Oct-18 18-Oct-18
All compress air storage tank 14-Mar-19 4-Dec-18 5-Dec-18
Out door unit to be shift above one meter

height in Mill office & PDO control room 14-Mar-19 30-Oct-18 30-Oct-18
DG set sub station 14-Mar-19 20-Nov-18 20-Nov-18
DG set sub station 14-Mar-19 24-Oct-18 24-Oct-18
portable equipment in mill area welding m/c 14-Mar-19 4-Dec-18 4-Dec-18
All MCC 17-Mar-19 26-Oct-18 2-Nov-18
All plant area 17-Mar-19 7-Dec-18 7-Dec-18
MCC room Battery bank 17-Mar-19 18-Dec-18 20-Dec-18
NA 18-Mar-19 28-Dec-18 29-Dec-18
all workshop 28-Mar-19 13-Mar-19 15-Mar-19
All GET Buckets 28-Mar-19 6-Mar-19 27-Mar-19

at all sites 28-Mar-19 26-Mar-19 27-Mar-19
Yes as per requirement. 28-Mar-19 26-Mar-19 28-Mar-19
In all mines 1-Apr-19 27-Mar-19 28-Mar-19

other mine site. 30-May-19 12-Apr-19 14-Apr-19

other mine site. 30-May-19 15-Apr-19 17-Apr-19
Yes 30-May-19 5-May-19 7-May-19
Yes 30-May-19 21-Apr-19 24-Apr-19
Yes 30-May-19 21-Apr-19 24-Apr-19
Yes 30-May-19 3-May-19 5-May-19

Yes 30-May-19 16-May-19 18-May-19
Yes 31-May-19 2-May-19 4-May-19
Yes 31-May-19 28-May-19 30-May-19
Yes 15-Jun-19 31-May-19 10-Jun-19

LED light to be provide on all sump to check
the level 28-Jun-19 22-Jun-19 23-Jun-19
all control room in plant 29-Jun-19 15-May-19 15-Jun-19
Zebra signage to provide on all bus pick up

& dropped out area 29-Jun-19 28-May-19 30-May-19
all conveyor belt at tail end pulley , tack up
pulley & feed side pulley 29-Jun-19 25-Apr-19 26-Apr-19
where approach not available clap may be
provide for stopping the vibration 29-Jun-19 21-May-19 21-May-19
NA 29-Jun-19 2-Jun-19 5-Jun-19
provided one no. to mines also 29-Jun-19 8-May-19 10-May-19
NA 29-Jun-19 15-Jun-19 17-Jun-19
in all chemical pumps 29-Jun-19 18-Jun-19 19-Jun-19

NA 29-Jun-19 5-Jun-19 6-Jun-19
where cameras are installed in open 30-Jun-19 13-Jun-19 13-Jun-19

Production Quality Cost Safety Delivery Morale Financial Benefit
NO NO Yes NO NO NO 0.5
Yes NO NO Yes NO NO 0
Yes Yes NO Yes NO NO 200000
NO Yes NO Yes NO NO 0
Yes Yes NO NO NO NO 0
NO Yes NO Yes NO Yes 0

Yes NO Yes NO NO NO 10
NO NO NO Yes NO NO 0
NO NO Yes Yes NO NO 0
NO NO Yes Yes NO NO 1
NO NO NO Yes Yes NO 0
NO Yes NO NO NO NO 0
Yes NO Yes NO NO Yes 0
Yes Yes NO Yes Yes Yes 0
Yes Yes Yes Yes Yes Yes 0
NO Yes Yes Yes NO NO 0.96
NO Yes Yes NO NO Yes 0
NO Yes NO NO Yes Yes 0
Yes Yes Yes Yes Yes Yes 1.86
Yes Yes Yes NO NO NO 6.3

NO NO Yes NO NO Yes 11.16
NO NO NO NO NO Yes 0
NO NO Yes NO NO NO 3
Yes NO NO NO NO Yes 0
Yes NO NO NO NO Yes 0
NO NO Yes NO NO Yes 3
Yes NO NO NO NO NO 0
NO NO NO Yes NO Yes 0
Yes Yes Yes Yes NO Yes 0
NO Yes NO Yes Yes Yes 0

Yes Yes Yes Yes NO NO 3
Yes NO Yes Yes NO Yes 0
Yes NO Yes Yes Yes Yes 0
Yes Yes Yes NO Yes Yes 0
Yes Yes Yes NO Yes Yes 0
Yes NO Yes Yes NO NO 110

NO Yes Yes NO NO NO 0
Yes NO NO NO Yes Yes 0
Yes NO Yes Yes NO NO 2
NO Yes NO Yes NO NO 0.2
NO NO Yes NO Yes NO 2
NO Yes NO Yes Yes Yes 0
NO NO Yes Yes Yes NO 0
Yes Yes NO NO Yes NO 0
Yes NO NO Yes NO Yes 0

NO Yes NO Yes Yes NO 0
NO NO NO NO NO Yes 0
ViewKaizen
https://ziep.hzlmetals.com/Pages/ViewKAIZ
EN.aspx?kaizen_Id=6329

Kaizen From April 20183

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No Vertical Unit Kaizen ID Kaizen Title

5570 Mines RDM MNS/RDM/KZN/201819/001 Savings in purchase of cartridge

6176 Mines RDM MNS/RDM/KZN/201819/006 Pump performance increase

Better access for water control for filling

Fill MCC water control level control to avoid

To avoid tailing lines leakage above fill plant

6181 Mines RDM MNS/RDM/KZN/201819/008 Cleaning of SIPX tank

6207 Mines RDM MNS/RDM/KZN/201819/014 Installation of siren on flotation crane

Installtion of tullu pump with automation in

6272 Mines RDM MNS/RDM/KZN/201819/018 Damage prevention of -35mRL Crane

Pull out test of exposed rock bolts for

Identification 2.4 m & 1.8 m rock bolt after

6332 Mines RDM MNS/RDM/KZN/201819/017 rerouting of EOT cable in crusher

Installation of density meter at tailing pump

Installation of a Surface Drilling water line to

6459 Mines RDM MNS/RDM/KZN/201819/024 Welding Machine :electrocution protection

Monitoring of Crusher screens for process

6536 Mines RDM MNS/RDM/KZN/201819/031 Hammer Stand

Metal Hammer replaced with Plastic

6631 Mines RDM MNS/RDM/KZN/201819/034 TCS on Royalty Updation in 26 AS

Detail Cost review analysis and presentation

Development saving by using unused X Cut

6671 Mines RDM MNS/RDM/KZN/201819/038 Reflector strip for parking

6676 Mines RDM MNS/RDM/KZN/201819/050 Rear Parking light mounting modification.

6677 Mines RDM MNS/RDM/KZN/201819/049 Re Shuffling of oil room and container

6678 Mines RDM MNS/RDM/KZN/201819/048 MU antena position change in new ST1030

6684 Mines RDM MNS/RDM/KZN/201819/042 Radiator mounting modification in ST 7

Use of spray paints instead of using manual

Water line laying for ball mill no-4 feed

Providing stand for welding machine to

6767 Mines RDM MNS/RDM/KZN/201819/053 WIRE PROTECTION

monitoring of shaft inset CCTV camera on

# SGA-Stripping of 350m in 100mRL Main

# SGA-Ventilation problem in lower east

Alternative source of filling 180mRL Stope-

#SGA-To draw power cable from -87mRL to

7351 Mines RDM MNS/RDM/KZN/201819/066 Safety guard made at jaw crusher

Retrofitting of reagent/chemical area crane

Fill Plant Transformer area Site improvement

Partition between engine and steering

Shifting the grinding and floation area

7807 Mines RDM MNS/RDM/KZN/201819/074 Increasing communication in NL

7810 Mines RDM MNS/RDM/KZN/201819/075 Stand for radiatopr frame

7812 Mines RDM MNS/RDM/KZN/201819/076 Direction of LHD movement

7814 Mines RDM MNS/RDM/KZN/201819/077 maintennace bay at door of container

7816 Mines RDM MNS/RDM/KZN/201819/078 zero power isolation in equipment

7817 Mines RDM MNS/RDM/KZN/201819/079 Turning of HEMM in workshop

Replacing the 6 inch foot valve to 4 inch foot

Installation of load cell in Mill EOT cranes for

Installation of proximity switch for providing

Electrical damaged Panel replacement of 5

Replacement of 5 Ton MCC side and 5 Ton

Replacement of OLD ball Mill 3 conventional

Installation of flame proof loght in grease

7972 Mines RDM MNS/RDM/KZN/201819/094 1220 Take up structure Restrengthen

7973 Mines RDM MNS/RDM/KZN/201819/093 Provide lock spring in 1296 Crusher

8009 Mines RDM MNS/RDM/KZN/201819/098 1085 DISCHARGE CHUTE MODIFICATION

8010 Mines RDM MNS/RDM/KZN/201819/097 1085 DECK PLATE FIXING WORK

8012 Mines RDM MNS/RDM/KZN/201819/095 lADDER TO BE MODIFY AT SCREEN HOUSE

seperate line placed for 7300B recirculation

Crusher crane current carring wheel inhouse

Aligned compound delivery header to

Shiftting of Pull card above conveyor guard