ENFOQUE DE LOS PROFESIONALES EN FUNCION DE LAS NECESIDADES DE LA MINERIA – PROYECTOS DE MEJORA

ING. RICARDO ZEBALLOS CASTILLO

INDICEAntecedentes

Habilidades Profesionales Ingenieriles

Optimización de Procesos Minería

Casos Proyectos Mejora

Conclusiones

Antecedentes La minería juega un rol importante en la economía peruana y mundial:

- Generación de valor agregado- Divisas- Impuestos- Inversión y - Empleo.

La minería es el principal sector exportador del país, ya que explicó hasta un 62% de las exportaciones peruanas. Debido a la caída de los precios internacionales de los minerales (cobre y oro especialmente) las exportaciones representan el 50% del total a finales de 2014. La actividad minera se ha consolidado como uno de los principales financistas del presupuesto nacional, representando en un momento hasta un 25% del total de ingresos tributarios del Perú.

Fuente: Banco Central de Reserva Peru

Tendencia Precio Minerales19 Nov 2015

Oro : 1.073,100 US$/tr

Cobre : 209,106 cUS$/lb

Plata : 14,210 US$/tr

QUE SE NECESITA ?

Habilidades Profesionales Optimización de los procesos Minería

Habilidades Ingenieros Especialización: Un mercado laboral sofisticado exige una clara especialización. Se debe abandonar la idea de saber ‘un poco de todo’ y orientar la carrera a un área específica.

Idiomas: El idioma inglés es el más requerido y es importante que su manejo se de a nivel avanzado. “Cuando vemos una hoja de vida que dice ingles intermedio sabemos que no sirve para determinadas posiciones. Hoy en día las personas tienen que ser bilingües para comunicarse con el creciente mercado de consumidores y con las empresas que vienen de otros países”.

Habilidades Ingenieros Soft skills:

Liderazgo

Inteligencia emocional

Resiliencia

Capacidad de gestión: saber dirigir y motivar a este equipo humano, también es importante que tenga conocimientos financieros y económicos aplicados a la empresa y tercero, debe tener un conocimiento técnico especifico a la labor que está desarrollando.

“

Optimización de Procesos – Minería

1. Costo Unitario ($/tm)

Costo Mercado (variable no controlable)

Producción (variable manejable y optimizable)

2. Free Cash Flow

Mayor ganancia económica al final de todo el proceso. Aca se buscan proyectos de mejora transversales a la organización.

MEJORA CONTINUA – MINA PEÑASQUITOUbicación

Empresa : Goldcorp Productos : Au, Ag, Pb, ZnProducción Anual : 700,000 Onz Au ( 2,000,000 onz equivalentes Au)Producción Mina : 700,000 Tm/diaProducción Quebradora : 130,000 Tm/dia

Evaluación Proyectos

1. Facilidad de Implementación

Estimar Costo de Implementación.

Complejidad

Tiempo (Mayor Valor)

2. Relativo al Valor de Ganancia

Producción

Beneficio Estimado

Probabilidad

Site Opportunities / Risks Heat Map: Peñasquito

Instructions1. For each opportunity and risk use table H1 and H2 to fill the yellow cells with scores 1 to 4 in table H3.2. For each opportunity estimate the actual value (if any) in US$ Millions in column K in table H3.3. Priority will be calculated in Column L and shown on the graph in tab "Heat Map Chart"

Table H1EASE TO IMPLEMENT Excellent Good Satisfactory Low

Points 4 3 2 1Estimated Cost to implement $ 0~250K $ 250~1M $ 1M~3M > $3MComplexity Area resources

required Site resources

requiredRegion/Corp

resources required

Highly specialized resources required

Time < 6 month 6~ 12 mo. 12~24 mo. >2 year

Table H2RELATIVE VALUE AT STAKE Excellent Good Satisfactory Low

Points 4 3 2 1Throughput Improve the

bottleneckIt is upstream of the bottleneck

It is downstream of the bottleneck

It is not part of the value stream

Free Cash Flow > $20M $ 10M~20M $ 5~10M $ 0~5MProbability of success (opportunity) orProbability of occurrence (risk)

>75% >50% >25% <25%

5 7 9 11 13 155

7

9

11

13

15

A. Mine Through Mill

B. Wall Steepening

C. Crusher OptimizationD. Flotation / Recovery

E. Load / Haul Optimization

F. Ball Mill Optimization

G. HPGR and Augmented feed

H. New waste area

I. Motor Timing change

Utility Management

Tire Management

Standby Cyclone Pump

Lighten BoxesEmulsion plant

Site Opportunities Heat Map

EASE

RE

LA

TIV

E V

AL

UE

EasierHarder

High Priority

Med Priority

Low Priority

Further review

Peñasquito Projects where fitPerforacion y Voladura

Carga y Acarreo

Chancado

Augmented Fee

d

Bolas

Molinos

Flotacion

16

Project MTM – Fragmentacion

L&H sOptimization

Chancadora Operacion

Aumento Alimentacion

Grinding Classification

Flotacion Recuperacionry

Focus Throughput Cost Throughput Throughput Throughput Recovery

New Waste Area

Cost

Motor Timing Change 930E

Cost

Hydraulic Oil Change 930E

Cost

Wall Steepening

Cost

Peñasquito Projects where fitDrill & Blast

Loading & Hauling

Crushing

Augmented Feed – HPGR - SAG Mill

Ball

Mill

Flotation

17

Project MTM – Fragmentation

L&H Optimization

Crushing Optimization

AF – HPGR Optimization

Grinding Classification

Flotation Recovery

Focus Throughput Cost Throughput Throughput Throughput Recovery

New Waste Area

Cost

Motor Timing Change 930E

Cost

Hydraulic Oil Change 930E

Cost

Wall Steepening

Cost

Peñasquito: O4E- Projects

PROJECT (KPI)KPI

Current

KPI Targe

t

All-in$ /Oz

Reduction

Target

All-in$ / OZ

Realized

2013 Free Cash

Flow Impact(USD MM)

2014Free Cash Flow

Impact(USD MM)

2013 Capital Investm

ent (USD MM)

Status Comments

Flotation Recovery (Rec

AuAgPbZn)

62%75%70%72%

63%76%71%73%

19.1 - 0.0 10.1 - 54%

- Rehabilitation Testing Stations concluded

- Installation of rubber in Bank B líne 1 (Pb)

-Promotor Aerofloat 7310 reactive testing

-Connection dose pumps Line 1 Zn- Oct 23 Scheduled meeting with SGS to define Expert System action plan

New Waste Area (KM Hauling distance)

7.3 4.6 6.0 - - 4.1 - 10%

-Sep 17 Future Leach pad expansion and stocks areas are defined . Future stock area will be filled with 20 MM tons waste base.

-Tech Services to deliver engineering by Oct 30 for permitting process (postponed)

-New dump areas will be identified in the mine next week

Engines Start up Timing Change (gal/hr)

53.3 52.77 1.1 - - 0.8 - 90%-RM delivered data to measures benefits.- Benefit definition by Oct 23

Hydraulic Oil Change (lts/year/truck)

700k 350k 1.2 - - 1.2 - 10%-Hydraulic test concluded and approval to go forward with all fleet

- Hydraulic oil will be change 2000 hrs

Steepen Walls 0 0 0 0 0 0 0 0%

- Study by Zero Base Budget group indicates low gain from steepening walls as only one area of the mine could support it. Project to be removed

18

Peñasquito: O4E- Projects

PROJECT (KPI)KPI

CurrentKPI

Target

All-in$ /Oz

Reduction Target

All-in$ / OZ

Realized

2013 Free Cash Flow

Impact(USD MM)

2014Free Cash Flow

Impact(USD MM)

2013 Capital

Investment

(USD MM)

Status

Comments

Throughput Increase (Ktpd Milled)

105.3 115 42.95 1.45 7.2 41.5 0.0 25% (2014 budget 110ktpd)

Mine Through Mill – Fragmentation (% Fines / % Coarse)

30%min10%max

30%min10%max 55%

- Contract crusher to stemming material in operation by Oct13

- Calibration split on line in process- 4 RCA workshops performed to analyze geological faults, level bank and energy contained issues and develop action plan with solutions

- Performed a workshop with Orica team to define opportunities of time use for Mixer trucks

Crusher Optimization

(Lost Hours/year) 2388 1753 25%

-Blockage workshops completed. Action plan in progress

-Long blunt tool installed in Rock breaker

-Mechanical failure RCA workshops scheduled for Oct 10 and initial actions defined

-Second timber installation in discharge crusher by Oct 20

HPGR and Augmented Feed

(Ktpd)12 22.5 15%

Bill of material defined and RFQ doneProductivity performance analyzed for HPGR and AFMonitoring plan defined and approved by team

Grinding Classification circuit

(Ktpd / P80)

105.3140um

115140um

30%

Arrived 12 ea Apex 7 ¼” to begin installation in Battery 2 Line 2 this week Monitoring plan defined and approved by teamAdditional 24 Apex will be purchased 19

Peñasquito: O4E-Projects

PROJECT (KPI)KPI

Current

KPI Target

All-in$ /Oz

Reduction Target

All-in$ / OZ

Realized

2013 Free Cash Flow

Impact(USD MM)

2014 Free Cash

Flow Impact

(USD MM)

2013 Capital Investment (USD MM)

Status

Comments

Load & Haul Opt. (Effective Utilization)

80% 83% 12.0 - - 20.0 - 20%

Shift change(Min)

40.5 6 60%

-Data validation with collect field data of 14 shift changes and dispatch information

-Current and future process map defined- Scheduled meeting with HR Oct 19 to define how handle Union in this project

- Improvements in shift change room scheduled next week

Truck speed(Km/h)

35 50 20%

- Areas will be used with increase speed was defined.

- Test 930 performed by Komatsu driver and Penasquito driver in order to show capabilities. Film video editing is in process

- Define training area and construction in progress 80%

- Oct 22 schedule meeting to define operator training with Komatsu

Diesel supply time(Delay time diesel)

17.6 11.1 15%

- KPIs and Target defined- Solution defined with pumps and lines system changes- Next week vendor will provide quotation

Dispatch optimization

(% Queue Truck at Shovels / Operating

Truck hours)

8.1% 6.5% 15%

-KPIs and target defined which is included already in Mine Daily report

-First workshop to define problems and causes

Total Site Value Creation

81.181.45

7.2 67.9 0

20

APPENDIX

Shift ChangeOpportunityEffective utilization.

ObjectiveShift change reduction time.

ApproachPit Shift Change population method.

Next Week

Human Resources meeting to define the implementation strategy, mainly about Union sensibilization to obtain support and sponsoring,Design of Truck Screen on Personnel Transport design and testRestriction to submit values on shift change false delay

Last Week

Mapping current process was analyzed and documentedValidate dispatch data for shovels and trucks for October 2012“To Be” map process was designed and documentedAction Tracker format was implemented

Truck Speed ChangeOpportunityEffective utilization.

ObjectiveTrucks velocity increase from 35 to 50 KPH

ApproachKomatsu 930E trucks on flat roads and descending ramps

Next Week

Screen optimization in shift change roomVideo edition of the truck demonstration will be ended and send to be reviewed by Manager teamKomatsu team run a operators evaluation

Last Week

Was performed and documented (filmed) a demonstration braking capabilities Komatsu 930E trucks, at different speedsDefine training area and construction in progress 80% advance The interview stage of the operators started with the U.S. Embassy to obtain visas to visit the Marigold mineAreas will be used with increase speed was defined.Action Tracker format was implemented

Dispatch optimizationOpportunityEffective utilization.

ObjectivePerformance improvements to facilitate and promote the effective utilization of the fleet

ApproachOptimization of assignment functions of Dispacth

Next Week

Oct 18 Second workshop with dispatchers and operators in order to define action planDesign and testing of Screen on Personnel Transport,

Last Week

2013 Data processed and analyzedKPI of Truck Queue time at loading was developed and implemented on the operational report: Queue time/Operating Time Truck (%)KPI included in Mine daily report to monitor dispatcher performanceOngoing Daily check list on dispatch system: start and after break lunchOngoing Daily meeting between dispatcher and mine supervisorAction Tracker format was implemented

Peñasquito: O4E-SWOT Projects

PROJECT (KPI)KPI

Current

KPI Targe

t

All-in$ /Oz

Reduction

Target

All-in$ / OZ

Realized

2014 Free Cash

Flow Impact(USD MM)

2015Free Cash Flow

Impact(USD MM)

2014 Capital Investm

ent (USD MM)

Status Comments

Flotation Recovery (Rec

AuAgPbZn)

62%75%70%72%

63%76%71%73%

19.1 - 0.0 10.1 - 54%

- Rehabilitation Testing Stations concluded

- Installation of rubber in Bank B líne 1 (Pb)

-Promotor Aerofloat 7310 reactive testing

-Connection dose pumps Line 1 Zn- Oct 23 Scheduled meeting with SGS to define Expert System action plan

New Waste Area (KM Hauling distance)

7.3 4.6 6.0 - - 4.1 - 10%

-Sep 17 Future Leach pad expansion and stocks areas are defined . Future stock area will be filled with 20 MM tons waste base.

-Tech Services to deliver engineering by Oct 30 for permitting process (postponed)

-New dump areas will be identified in the mine next week

Engines Start up Timing Change (gal/hr)

53.3 52.77 1.1 - - 0.8 - 90%-RM delivered data to measures benefits.- Benefit definition by Oct 23

Hydraulic Oil Change (lts/year/truck)

700k 350k 1.2 - - 1.2 - 10%-Hydraulic test concluded and approval to go forward with all fleet

- Hydraulic oil will be change 2000 hrs

Steepen Walls 0 0 0 0 0 0 0 0%

- Study by Zero Base Budget group indicates low gain from steepening walls as only one area of the mine could support it. Project to be removed

25

MGM: Jesus Gutierrez

Peñasquito: O4E-SWOT Projects

PROJECT (KPI)KPI

CurrentKPI

Target

All-in$ /Oz

Reduction Target

All-in$ / OZ

Realized

2013 Free Cash Flow

Impact(USD MM)

2014Free Cash Flow

Impact(USD MM)

2013 Capital

Investment

(USD MM)

Status

Comments

Throughput Increase (Ktpd Milled)

105.3 115 42.95 1.45 7.2 41.5 0.0 25% (2014 budget 110ktpd)

Mine Through Mill – Fragmentation (% Fines / % Coarse)

30%min10%max

30%min10%max 55%

- Contract crusher to stemming material in operation by Oct13

- Calibration split on line in process- 4 RCA workshops performed to analyze geological faults, level bank and energy contained issues and develop action plan with solutions

- Performed a workshop with Orica team to define opportunities of time use for Mixer trucks

Crusher Optimization

(Lost Hours/year) 2388 1753 25%

-Blockage workshops completed. Action plan in progress

-Long blunt tool installed in Rock breaker

-Mechanical failure RCA workshops scheduled for Oct 10 and initial actions defined

-Second timber installation in discharge crusher by Oct 20

HPGR and Augmented Feed

(Ktpd)12 22.5 15%

Bill of material defined and RFQ doneProductivity performance analyzed for HPGR and AFMonitoring plan defined and approved by team

Grinding Classification circuit

(Ktpd / P80)

105.3140um

115140um

30%

Arrived 12 ea Apex 7 ¼” to begin installation in Battery 2 Line 2 this week Monitoring plan defined and approved by teamAdditional 24 Apex will be purchased 26

MGM: Jesus Gutierrez

Peñasquito: O4E-SWOT Projects

PROJECT (KPI)KPI

Current

KPI Target

All-in$ /Oz

Reduction Target

All-in$ / OZ

Realized

2013 Free Cash Flow

Impact(USD MM)

2014 Free Cash

Flow Impact

(USD MM)

2013 Capital Investment (USD MM)

Status

Comments

Load & Haul Opt. (Effective Utilization)

80% 83% 12.0 - - 20.0 - 20%

Shift change(Min)

40.5 6 60%

-Data validation with collect field data of 14 shift changes and dispatch information

-Current and future process map defined- Scheduled meeting with HR Oct 19 to define how handle Union in this project

- Improvements in shift change room scheduled next week

Truck speed(Km/h)

35 50 20%

- Areas will be used with increase speed was defined.

- Test 930 performed by Komatsu driver and Penasquito driver in order to show capabilities. Film video editing is in process

- Define training area and construction in progress 80%

- Oct 22 schedule meeting to define operator training with Komatsu

Diesel supply time(Delay time diesel)

17.6 11.1 15%

- KPIs and Target defined- Solution defined with pumps and lines system changes- Next week vendor will provide quotation

Dispatch optimization

(% Queue Truck at Shovels / Operating

Truck hours)

8.1% 6.5% 15%

-KPIs and target defined which is included already in Mine Daily report

-First workshop to define problems and causes

Total Site Value Creation

81.181.45

7.2 67.9 0

27

MGM: Jesus Gutierrez

Proyectos Estatus de DesarrolloSTATUS GENERAL

Pasos Fragmentació

n

Trituración

AF HPGR

Clasificación

Flotación

L&H Velocida

d

L&H Hot

Change

L&H Fuel

L&H Dis

patch

Waste

Area

Engine

Start

Hyd Oil

Chan

1. Diagnosticar

2. Generar Ideas

3. Implementar

28

Evaluar Resultados

Estandarizar

Definir el problema

Establecer Metas

Analizar Causas

Generar Soluciones

Planear & Ejecutar

Week of Sep 25 – Oct 8 highlights

Major focus in all projects related to Mine defining KPIs, targets and benefits

Use of stemming produced by contractor crushing plant

Test performed by Komatsu instructor and Penasquito driver. Test was video and is in edition process

7 ¼” Apex for testing arrived at mine site and it will be installed in a cyclone bank for testing

Hydraulic Oil testing concluded and oil frequency change will be 2000 hrs

New Waste area project will include possible additional dump areas and not only Leach pad project area

29

APPENDIX

Shift ChangeOpportunityEffective utilization.

ObjectiveShift change reduction time.

ApproachPit Shift Change population method.

Next Week

Human Resources meeting to define the implementation strategy, mainly about Union sensibilization to obtain support and sponsoring,Design of Truck Screen on Personnel Transport design and testRestriction to submit values on shift change false delay

Last Week

Mapping current process was analyzed and documentedValidate dispatch data for shovels and trucks for October 2012“To Be” map process was designed and documentedAction Tracker format was implemented

Current Shift Change Flow Map

Target Shift Change Flow Map

Truck Speed ChangeOpportunityEffective utilization.

ObjectiveTrucks velocity increase from 35 to 50 KPH

ApproachKomatsu 930E trucks on flat roads and descending ramps

Next Week

Screen optimization in shift change roomVideo edition of the truck demonstration will be ended and send to be reviewed by Manager teamKomatsu team run a operators evaluation

Last Week

Was performed and documented (filmed) a demonstration braking capabilities Komatsu 930E trucks, at different speedsDefine training area and construction in progress 80% advance The interview stage of the operators started with the U.S. Embassy to obtain visas to visit the Marigold mineAreas will be used with increase speed was defined.Action Tracker format was implemented

Dispatch optimizationOpportunityEffective utilization.

ObjectivePerformance improvements to facilitate and promote the effective utilization of the fleet

ApproachOptimization of assignment functions of Dispacth

Next Week

Oct 18 Second workshop with dispatchers and operators in order to define action planDesign and testing of Screen on Personnel Transport,

Last Week

2013 Data processed and analyzedKPI of Truck Queue time at loading was developed and implemented on the operational report: Queue time/Operating Time Truck (%)KPI included in Mine daily report to monitor dispatcher performanceOngoing Daily check list on dispatch system: start and after break lunchOngoing Daily meeting between dispatcher and mine supervisorAction Tracker format was implemented