Effect of Automation on the Productivity of a Coal Packaging Plant

Transcription

1 Çukurova Ünverses Mühendslk Mmarlık Faküles Dergs, 33(3), ss , Eylül 2018 Çukurova Unversy Journal of he Faculy of Engneerng and Archecure, 33(3), pp , Sepember 2018 Effec of Auomaon on he Producvy of a Coal Packagng Plan Mehme Nur BAHŞİŞ 1, Yaşar KASAP *2 1 Mnng Engneer, Slop Conrol Drecorae, Şırnak 2 Dumlupınar Unversy, Faculy of Engneerng, Deparmen of Mnng Engnerng, Küahya Gelş arh: Kabul arh: Absrac Auomaon provdes drec conrbuon o a counry's economy and npus o he manufacurng secor, and by means of auomaon akng place n many areas of mnng ndusry, a safe, economcal and effcen producon can be realzed for he secor n concern. Usng he Malmqus ndex oal facor producvy, hs manuscrp focused on and nvesgaed he change n operaonal producvy of Wesern Lgne Corporaon (WLC) as a resul of he converson of he packagng plan no a fully auomaed sysem. The resuls ndcaed ha he producvy score would ncrease by 16.1% due o he converson of he curren sysem no a fully auomaed sysem. The operaonal producvy s also expeced o ncrease consderng he reducons n he amoun of energy used, he number of workers employed and he number of producon losses. Keywords: Coal packagng, Auomaon, Producvy, Malmqus oal facor producvy Kömür Torbalama Tess Vermllğnde Oomasyonunun Ekler Öz Ülke ekonomsne doğrudan yapığı kakılar, mala sekörüne sağladığı grdler nedenyle büyük öneme sahp olan madenclk sekörünün brçok alanında gelşrlen oomasyonlar le emnyel, ekonomk ve verml ürem gerçekleşrleblmekedr. Bu çalışmada Garp Lnyler İşlemes kömür orbalama essnn am oomak sseme dönüşürülmes necesnde şleme vermllğndek değşm ncelenmeye çalışılmışır. Elde edlen sonuçlara göre orbalama essnn, am oomak sseme çevrlmes le vermllk değernde %16,1 lk br arış olacağı esp edlmşr. Kullanılan ener mkarlarındak, çalışırılan şç sayılarındak ve ürem kayıplarındak azalmalar dkkae alındığında şleme vermllğnde de arış olacağı düşünülmekedr. Anahar Kelmeler: Kömür orbalama, Oomasyon, Vermllk, Malmqus oplam fakör vermllğ * Sorumlu yazar (Correspondng auhor): Yaşar KASAP, yasar.kasap@dpu.edu.r Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül

2 Effec of Auomaon on he Producvy of a Coal Packagng Plan 1. INTRODUCTION Snce he day human bengs came no exsence, hey have always been n pursu of new dscoveres, worked hard o go one sep furher regardless of he era hey lved n, and, afer a ceran pon, sared o seek ways of obanng more gans wh less effor and larger profs wh smaller budges. All he nvenons ha can be consdered as he resuls of hs ques acually make up he concep of auomaon. Auomaon can be descrbed as a process n whch asks n he ndusral secor, scenfc research and he feld of managemen are performed whou human labor by machnes. Alhough he benefs of auomaon nclude hgh performance and ob secury, low operaonal cos, more effcen use of space and machnery, organzaonal convenence, and error-free, hgh qualy and sandardzed producon, here are some dsadvanages of auomaon such as people beng replaced by machnes, sysem falure, sysem complexy, and hgh nvesmen cos [1]. Due o echnologcal advancemens over he las decades, sgnfcan changes have occurred n boh producon (e.g. hgh producon rae, work safey, low operang coss, hgh qualy and sandardzed producs, ec.) and n he srucure of labor force. Developmens n scence and echnology and demand for he ncrease n saff qualfcaons and he qualy of producs have gven prory o producvy. Producvy nvolves achevng producon n hgher quany and qualy wh less cos and less equpmen. There s a grea deal of research on he posve effecs of auomaon on effcency [2-5]. Effors o ncrease producvy prmarly nvolve corporaons, whch make up he core of he economy of a counry, and her producon uns, whch make up he backbone of hese corporaons. By means of adapng evolvng echnology o busnesses, effors o ncrease producvy brng abou numerous benefs such as ncreased producon and work safey, and reduced operang cos. There s consderable research on he posve conrbuons of auomaon for safe and economcal producon hanks o he developmens observed n recen years n measuremen and conrol sysems relaed o mnng echnology [6-10]. Wh he use of advanced echnology n he mnng secor, large capacy excavaors and draglnes are now used n open-p mnng. Conveyor bels n housands of klomeers n lengh are an ndspensable means of ranspor n open-p mnng. Gan rucks are used for ransporaon where conveyor bels are no used. The use of fully mechanzed producon sysems n underground mnng applcaons s ncreasng day by day. For example, plow or drum cuer-loaders are now used for excavaon, sheld suppor are used for forfcaon, and chan and bel conveyors are used as a means of effecve and effcen ranspor n underground mnng. Almos all of hese ground and underground asks can be operaed auomacally or remoely [11]. U.S. Naonal Insue of Sandards and Technology has been workng on mnng auomaon sysems n he Deparmen of Roboc Sysems. Ther sysem proec nvolves connuous observaon n underground mnng, he use of machnes remoely, performng varous measuremens, managemen of producon, producvy and forfcaons. The bes example of auomaon n surface mnng s exper sysem guded auomaed ruck sysem. Wh hs sysem, loadng, ransporaon and unloadng operaons are performed whou human nervenon. An nellgen drllng machne based on arfcal nellgence, whch was developed o be used n gas and ol searches, deecs all he parameers dependng on he drlled envronmen, uses drllng machne auomacally, nsanly measure he wear occurrng n drll bs, and gves nformaon abou he cos of drllng. More mporanly, hgh-ech applcaons can mprove workers healh and safey n he mnng secor, whch has always had he wors workng safey condons [11]. The am of hs sudy s o nvesgae he change n operaonal producvy of Wesern Lgne 162 Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül 2018

3 Mehme Nur BAHŞİŞ, Yaşar KASAP Corporaon (WLC) as a resul of he converson of he packagng plan no a fully auomaed sysem by usng he Malmqus ndex oal facor producvy. Approxmaely 85% of he lgne producon n WLC s from opencass and 15% s from underground mnng plans. The annual producon capacy s abou 6.3 mllon ons, and 1 mllon ons of hs amoun s from underground producon. Ths sudy ams o esmae he effec of he converson of he curren packagng plan no a fully auomaed sysem on producvy changes and operaonal producvy. 2. METHODOLOGY Paramerc effcency measuremens assume ha he producon funcons of fully effcen uns are known. Snce he producon funcon s never known n pracce, Farrell [12] suggesed ha he funcon can be esmaed from sample daa. The frs proposal was evaluaed by Charnes, e all. [13]. The frs sep n nonparamerc approach o measuremen of effcency, whch s used for comparave effcency analyss, s o deermne enveloped surfaces (effcen froner) ha cover he lnear combnaons and effcen observaons of he decson makng uns (DMU) whch carry ou he same producon acves. Then he effcency scores and radal dsances (from he cener) of neffcen uns whn he enveloped surface are calculaed [14]. In order o calculae he Techncal Effcency (TE) for k h DMU (he decson makng un n queson), he followng lnear programmng model s used. mn k (1) n Y r s r Y 1 rk (r = 1,2,...,s), (2) n X s k 1 X k (=1,2,...,m) (3), s, s r 0 (=1,2,...,n). (4) In he model ha s esablshed for effcency measuremen o be performed under npu mnmzaon, he obecve s o keep oupus consan bu npus a a mnmum level (Equaon 1). Equaon 2 ses nvolve comparson of he oupus kep consan n DEA (Daa Envelopmen Analyss) carred ou under npu mnmzaon. Wh hs consran, r h oupu of each DMU wll no be greaer han he maxmum lnear combnaon of he uns consung he effcen froner. The consrans where mnmzaon s sough for he npus n neffcen DMUs are shown n he Equaon 3. Equaon 4 represens he consrans o be non negave [15]. In order for a DMU o be consdered effcen, opmal k has o be equal o 1 all slack varable scores have o be zero ( s k, s rk 0 ). The symbols used n he formulaon of nonparamerc lnear programmng are defned below: n he number of decson-makng uns nvolved n comparson, s he number of oupus ganed from he producon, m he number of npus used n he producon, = (1,2,.,n) se of all decson-makng uns, k = (1,2,.,n) se of decson-makng uns aken no consderaon, r = (1,2,.,s) se of all oupus, = (1,2,.,m) se of all npus, y R + s vecor of oupus (y 1, y 2,,y s) = sn x R + m vecor of npus (x 1, x 2,,x m) = mn Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül

4 Effec of Auomaon on he Producvy of a Coal Packagng Plan λ he vecor of densy varables gvng npusoupus wegh averages = k1 he relave (compared o oher uns, ) wegh value of k decson un measured for effcency n npu-orened, k he scaler varable (effcency score) ryng o decrease all npus of k DMU, whch s consdered o oban he bes froner, Y r he r h oupu amoun produced by decson un, Y rk he r h oupu amoun produced by decson un k, X he h npu amoun used by decson un, X k he h npu amoun used by decson un k, As a form of sac analyss, Daa Envelopmen Analyss performs analyses usng daa from decson makng uns n a sngle perod. However, a decson makng un whch was denfed o be effcen before may lose s effcency and reference qualy. In hs respec, n effcency evaluaon process, he MPI (Malmqus Toal Facor Producvy Index) was developed o examne he changes ha may occur over me. The MPI, whch was obaned by addng he funcons of dsance o he Farrell [12] measure of echncal effcency, measures he varaon n wo uns oal facor producves as he proporon of he dsances from a common echnology. Dsance funcon s used o defne mul-npu and mul-oupu producon echnologes whou specfyng obecves such as cos mnmzaon or prof maxmzaon. The npu dsance funcon consders a producon echnology by lookng a a mnmal proporonal conracon of npu vecor, gven an oupu vecor, whle he oupu dsance funcon characerzes a maxmal proporonal expanson of he oupu vecor, gven an npu vecor [16]. Ths sudy used he oupu dsance funcon because was suable for he analyss whch was conduced o nvesgae he effcency changes of he decson makng uns n he consdered years [12,16]. Grfell-Tae and Lovell [17] showed ha usng he assumpon of varable reurns o scale when calculang he dsance funcons requred for MPI (Malmqus Toal Facor Producvy Index) would no accuraely measure he changes (gan or loss of producvy) n Toal Facor Producvy (TFP) ndex. For hs reason, he ndex needs o be calculaed under he assumpon of consan reurns o scale [17]. Inpu based analyss s approprae snce he producon of coal baggng plans s made accordng o he demand of he producon marke. The npu dsance funcon s D x, y max θ : ( x, y) Ly (5) If y vecor s an elemen of he possble producon se of L(y) effcen froner, he dsance funcon D(x,y) wll have a value smaller han or equal o one. Accordng o he npu beween perod and he subsequen (+1) perod and whn he framework of dsance funcon, MPI s calculaed as MPI D y 1, x 1 D 1 y 1, x 1 D 1 y, x D y, x (6) where D (x, y) represens he dsance of perod o +1 perod echnology. An MPI value greaer han 1 ndcaes ha here s an expanson of oal facor producvy from perod o +1 perod whle an MPI value smaller han 1 shows a conracon n oal facor producvy [18]. MPI consders changes n producvy accordng o wo separae componens: echncal effcency change and echnologcal change. Techncal effcency change (TE) provdes an assessmen of he process n whch decson-makng uns approach he effcen froner whereas echnologcal change (TC) provdes he change of he effcen froner over me [17,19]. 164 Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül 2018

5 Mehme Nur BAHŞİŞ, Yaşar KASAP When Equaon (6) s revsed, y y 1y 1 y D, x D, x D, x MPI (7) 1 D y, x D, x D y, x (TE) (TC) where he rao ousde he square brackes measures he change n he oupu-orened measure of Farrell echncal effcency beween perods and +1. In oher words, he effcency change s equvalen o he rao of he echncal effcency n perod +1 o he echncal effcency n perod. The remanng par of he ndex n Equaon 7 s a measure of echncal change. I s he geomerc mean of he shf n echnology beween he wo perods, evaluaed a x +1 and also a x [16]. MPI = TE TC (8) Non-paramerc lnear programmng mehod s he mos popular mehod whch s used o esmae he dsance funcons ha are requred o form MPI. When here s a suable panel daa se, he requred dsances can be calculaed by usng nonparamerc lnear programs by means of hs mehod. Four dsance funcons mus be calculaed o measure he changes TFP beween he wo perods for any h npu and hs requres he soluon of four Lnear Programmng (LP) problems. The LPs requred under he assumpon of consan reurns o scale are D x, y 1 D x, y 1 maxθ k n λ y.θ 1 y r rk k n λ x x 1 1 λ 0 maxθ k n λ y 1 n λ 1 λ 0 r x y rk.θ k x (9) (10) 1 1 D x, y 1 1 D x, y 1 maxθ k n 1 1 λ y.θ 1 y r rk k n 1 1 λ x x 1 1 λ 0 maxθ k n λ y 1 n λ 1 λ 0 r 1 y rk.θ k 1 x x (11) (12) Deermnng hese defned dsance values by usng Equaons 9-12 for all me perods and years requres he soluon of, where n n 3 2 represens he number DMUs and shows he number of perods, lnear programmng models [18]. Snce here were 2 parameers analyzed and 12 monhs (as perods of me) n hs sudy, a oal of 68 lnear programmng models were solved so ha he analyses could be carred ou. 3. APPLICATION There are hree packagng plans n WLC. Currenly, however, only Tunçblek plan s used because he capacy of Tunçblek packagng plan s already compable wh he amoun of producon. The plan offers pure and dus-free producs o cusomers by washng he run of mne coal comng from he WLC cass n he coal washng plans and packagng. The coal mm n sze s weghed n he amoun of 25 kg by he elecronc scales. When he coal n a scale reaches 25 kg, he coal s poured from he scale no he fllng reducer. Afer a worker places an empy coal bag o he reducer, he coal n he scale s poured no he reducer by means of a swch and, from here, s flled no he empy coal bag. Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül

6 Effec of Auomaon on he Producvy of a Coal Packagng Plan I akes approxmaely 12 seconds for a reducer o fll a coal bag. In order o ncrease producon, here are wo scales mouned on each coal-fllng reducer. When he worker responsble for he coalfllng reducers unloads he coal n one of he scales no an empy coal bag by means a reducer, he oher scale s loaded wh coal. Ths ncreases coal-fllng rae. The bags loaded wh coal are sen o he sewng bel and a worker sews hese bags wh a sewng machne. Afer ha, he bags are loaded o rucks hrough he loadng lne. There are currenly 24 coal fllng reducon and 24 sewng machnes n he WLC Coal Packagng Un, whch requres assgnng 48 workers. Togeher wh hese 48 workers, here should be a oal of 80 workers n a shf ncludng egh loaders, four cleaners, hree elecrcans, wo welders, four manenance workers, one echncan, one shf supernenden, four ruck drvers, 2 loader operaors, one sweeper operaor, one shuner, and sewng machne worker. Therefore, he un needs a oal of 240 workers for he hree shfs n a day. On he oher hand, here could also be varaons n he coal fllng reducon, whch s operaed accordng o he daly demand for bagged coal. Ths consequenly causes a change n he number of workers n he plan a a specfc me. The amoun of elecrc power used n he coal packagng uns depends on producon and, herefore, energy consumpon ncreases dependng on he number of uns ha are run when he amoun of bagged coal ncreases. Thanks o he advances n echnology and auomaon, fully auomaed packagng sysems could brng abou sgnfcan benefs n all secors as well as mnng ndusry n erms of ncreasng effcency. Fully auomaed packagng sysems can be used n packagng maerals such as agrculural maerals (e.g. seeds, beans, grans, corn, grass seed, and organc pelle ferlzer), food (e.g. whea, corn, rce, cereals, semolna, whea flour, sugar, sal, and coffee), fodder (e.g. anmal feed), norganc ferlzers (e.g. urea and rock phosphae), perochemcals (e.g. plasc granules, resn powder, ec.), buldng maerals (e.g. sand and gravel), and fuel (e.g. coal and wood pelles). The prmary obecve of fully auomaed packagng sysems s o ncrease effcency by achevng hgh-speed producon (.e. 30 bags per mnue) and reducng losses occurrng due o low producon [20]. In hs sudy, he auhors analyzed he daa abou he cos and producon of a fully auomaed packagng plan desgned for a sugar facory n Turkey. They found based on hs daa ha he cos of a fully auomaed coal packagng sysem o be bul for WLC would be lower han he cos of he curren coal packagng sysem n he las wo years (WLC has been payng conracors for coal packagng snce 2004). The fully auomaed packagng sysem descrbed n Table 1 s capable of auomacally weghng (25 kg) he coal fed o he un bunker from he crusher and hen feedng o he producon reducer. The vacuum arms of he machne auomacally receve he bags n he bunker and nser hem n he fllng reducer. Afer he bags are flled wh coal and ransferred o he sewng bel, wo mechancal arms ake hem o he sewng machne. Afer hey are sewn, hey are loaded ono rucks by means of he loadng bel. Fgure 1, Fgure 2, and Fgure 3 show pcures aken durng bag placng, bag fllng and bag sewng processes for he curren sysem agans he fully auomaed sysem. The fully auomaed verson of he baggng un does no requre any saff for he processes. However, abou 10 workers per shf are needed for cleanng he un and for placng new empy bags o he bag conaner. Therefore, a oal of 30 workers wll be needed because he corporaon operaes on hree shfs. In he curren sysem, he oal number of employees vares beween 38 and 238 dependng on he demand for coal. Therefore, he fully auomaed verson of he baggng un wll reduce he cos of labor, whch s he larges em among he npus, by 80%. 166 Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül 2018

7 Mehme Nur BAHŞİŞ, Yaşar KASAP Table 1. The feaures of he curren coal packagng plan and s fully auomaed verson The Curren Coal Packagng Plan The Fully Auomaed Coal Packagng Sysem Maeral Coal Coal Densy (ons/m 3 ) Weghng range (kg) Screen resoluon Unavalable 1/ Inernal resoluon of he ndcaor (b) Sensvy (%) Upper Bunker Capacy (l) Reducer capacy (l) Elecrcy 400 V AC/ Hz 400 V AC/ Hz Elecrcy consumpon (kw/h) Weghed uns per hour Capacy of producon (ons/ day) Bag sewng Irregular and defecve Approprae and flawless Wegh dsplay Unavalable Yes n 4 dgs Fas Slow roaon Unavalable The sysem can be programmed Tolerance The sysem remans whn he The sysem connues upper and lower lms; The producon even he sysem hals when he olerance olerance level s exceeded. level s exceeded. Toal number of bagged uns Unavalable Dsplayed on he screen. Toal wegh of bagged produc Unavalable Dsplayed on he screen. Toal duraon of packagng Unavalable Dsplayed on he screen. Level conrol for upper bunker Manual conrol by a worker. Auomac conrol Alarm Unavalable Informaon provded by he sysem and he operaor s nofed. a) b) Fgure 1. a) Bag placng process n he curren packagng plan. b) Bag placng process n he fully auomaed sysem Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül

8 Effec of Auomaon on he Producvy of a Coal Packagng Plan a) b) Fgure 2. a) Bag fllng process n he curren packagng plan. b) Bag fllng process n he fully auomaed sysem a) b) Fgure 3. a) Bag sewng process n he curren packagng plan. b) Bag sewng process n he fully auomaed sysem The maxmum possble quany of producon performed by he 24 producon reducers n he curren coal baggng plan s 4700 on/day. The amoun of producon n a producon reducer s 196 ons per day (4700/24) and ons per hour (196/24). Ths amoun of producon s equal o 136 kg/mn (81597/60). Because each coal bag s 25 kg, 5-6 coal bags can be prepared per mnue (136/25). In he proposed fully auomaed verson of he baggng sysem, on he oher hand, 10 bags of coal can be produced n a reducer per mnue. The amoun of producon n a producon reducer wll 168 Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül 2018

9 Mehme Nur BAHŞİŞ, Yaşar KASAP be abou 250 kg per mnue (25 10) and approxmaely 15 ons per hour (60 250). Because here are 24 producon reducers n he un, hourly producon wll be 360 ons and daly producon wll be 8640 ons. Ths resuls n an ncrease n he producon capacy by 83.8% (Table 2). Table 2. The capaces of he curren coal packagng sysem and he fully auomaed verson The Curren Coal Packagng Plan The Fully Auomaed Coal Packagng Sysem Daly amoun of producon (ons/day) Per reducer, Amoun of producon per day (ons/day) Amoun of producon per hour (ons/hr) 8 15 Amoun of producon per mnue (kg/mn) Number of bags o be flled per mnue (no/mn) I s esmaed ha he amoun of producon realzed n 24 hours n he curren coal packagng plan could be realzed n 13 hours n he fully auomaed verson of he sysem. In erms of he amoun of energy used n he un, here wll be a reducon n he daly amoun of energy used by approxmaely 46%, whch s expeced o mprove he energy effcency of he corporaon Daa Used n Analyss Alhough fully auomaed packagng sysems are used n many ndusres, our counry does no have such a sysem n he coal ndusry. The auhors analyzed he daa abou he cos and producon of a fully auomaed packagng plan desgned for a sugar facory n Turkey o esmae he possble changes n he producvy of he curren coal packagng sysem of WLC. The producvy of he curren packagng plan and he fully auomaed packagng sysem was analyzed usng he Malmqus TFP based on he daa from he year In hs analyss, he decson-makng uns (DMUs) consdered were he curren packagng plan and he fully auomaed packagng sysem. The perods of me aken no consderaon were he 12 monhs of 2012 (January,, December). In he curren packagng plan, here are losses of coal producon occurrng due o mproperly sewn, or orn or ncorrecly loaded coal bags. However, s esmaed ha here wll be lle or no losses of producon n he fully auomaed packagng sysem. The amoun of coal fed o he packagng uns, he number of workers hred n he packagng uns, and he amoun of energy used n he packagng uns were consdered as he npus, and he amoun of bags of coal ha were produced was consdered as he oupu. Whle oupus can be kep consan n order o ncrease producvy n he non-paramerc effcency analyss, npus can be kep consan n order o ncrease oupus as well. Alhough he Malmqus TFP ndex examnes he effcency changes of DMUs whou npu mnmzaon or oupu maxmzaon, because s based on he non-paramerc effcency analyss, an ncrease n producvy s possble by reducng he amoun of he coal fed o he plan, whch s consdered as an npu. However, reducng he amoun of he coal fed o he plan s no opon so ha he plan can operae a full capacy. Deermnng he npus ha are compable wh he srucure of he models used s crcal for obanng accurae Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül

10 Effec of Auomaon on he Producvy of a Coal Packagng Plan resuls. For hs reason, he amoun of coal ha s fed o he plan were negaed (1/The Amoun of he Coal Fed) and ncluded n he analyss. Table 3 shows he daa from he year 2012 for he curren packagng plan. Table 3. Daa from he year 2012 for he curren packagng plan DMU Quany of Bagged Coal Produced (ons) Quany of Coal Fed (ons) Number of Workers (no/days) Amoun of Energy (kwh) January February March Aprl May June July Augus Sepember Ocober November December MEAN The proposed fully auomaed coal packagng sysem wll perform producon accordng o he demand per un of me and wll sop auomacally when he demand s me. Therefore, here wll a reducon n energy consumpon. Wha s more, here wll no longer be a need for hrng a large labor force o operae he un and he un wll be operaed wh a oal of 25 workers per day. In he curren sysem, he number of workers could vary dependng on he demand (Table 4). A maxmum level of producon wll be acheved along wh decreasng amoun of energy and he number of workers. I wll be possble o smulaneously run he 24 coal fllng reducers and o realze producon durng 24 hours of he day. The curren crcumsances requre ha asks should be organzed n advance and he workers o be hred for each of he coal fllng reducers (e.g. fllng workers, sewng machne workers, and loaders) need o be provded wh clearly descrbed asks. In addon, s mpossble for hese workers o work non-sop for 8 hours n a shf. These workers can work for hours due o reasons such as changng shfs, lunch break, and so on. Table 4. The amoun of energy o be consumed by he fully auomaed coal packagng sysem n he year 2012 Task Amoun of he Energy o be Consumed (kwh) Acvang Bunker Upper Bel 1.50 Runnng Bunker Upper Bel 4.00 Bunker Feedng Bel 7.50 Auomaed Coal Packagng Toal Amoun of Energy o Be Used n One Un Toal Amoun of Energy o Be Used n Three Uns Amoun of Energy o Be Used Daly Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül 2018

11 Mehme Nur BAHŞİŞ, Yaşar KASAP Table 5. Amoun of energy consumed per monh n 2012 Quany of Bagged Amoun of Energy Consumed Number of Days* Coal Produced per Monh (kwh)** January February March Aprl May June July Augus Sepember Ocober November December * Number of Days When Coal s Produced n he Correspondng Monh = Quany of Bagged Coal Produced /8640 (daly amoun of producon) ** Amoun of Energy Consumed per Monh = (amoun of energy consumed per day) Number of Days Among he daa aken no consderaon, he amoun of coal produced and he amoun of coal fed were consdered equal because he fully auomaed packagng sysem s expeced o have no coal losses. In such a sysem, s esmaed ha he un wll operae wh 25 employees on a daly average snce he sysems operaes n only one shf per day n February, March, and Aprl due o he low coal demand n hese monhs and producon s performed n hree shfs per day dependng on demand durng he oher monhs. The amoun of energy ha would have been consumed s calculaed accordng o he amoun of he coal fed (he amoun of he bagged coal produced) and shown n Table 5 and Table 6. m he number of npus used n he producon (he quany of coal fed o he packagng uns, he number of workers n he packagng uns, he amoun of energy used n he packagng uns), k {1,2} se of decson-makng uns aken no consderaon, r {1,2} se of all decson-makng uns, {1} se of all oupus, {1,2,3} se of all npus, 3.2. Producvy Change n he Packagng Sysem 12 monhs n a year (January, February,., December) The ses and parameers used n he effcency analyses are defned below: n coal packagng uns (he curren plan and he proposed fully auomaed sysem), s he number of oupus ganed from he producon (he quany of bagged coal produced n he packagng uns), The producvy change of he packagng sysems was evaluaed usng he Malmqus TFP ndex. DEAP 2.1 was used n he analyses. Daa from he fully auomaed coal packagng sysem gven n Table 6 and daa from he curren coal packagng un gven n Table 3 for he year 2012 were compared and conrased on a monhly Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül

12 Effec of Auomaon on he Producvy of a Coal Packagng Plan bass usng he Malmqus oal facor producvy mehod. Fgure 4 shows he resuls obaned. The producvy score was expeced o be hgh consderng he fac ha here would no be any varaon n he number of workers as coal packagng would be performed by machnes n he fully auomaed packagng sysem, less energy would be consumed as equpmen compable wh he amoun of coal would be ulzed, and here would no be any producon losses n hs sysem. In fac, n comparson wh he fully auomaed coal packagng sysem, he mean effcency scores of he curren sysem was calculaed as 83.9%. The coal losses durng he packagng process, he number of exra workers, and overconsumpon of energy could be effecve on hs neffcency. Converson of he curren GCL packagng plan no a fully auomaed sysem s expeced o cause an ncrease n producvy by 16.1%. Consderng he reducons n he energy consumpon, he number of workers hred, and he losses n bagged coal producon n he un, as well as n he enre facly, he overall operaonal producvy of he corporaon wll be mproved as well. On he oher hand, more comprehensve research s requred o be able o clearly denfy he ncrease rao n he operaonal producvy of he corporaon. In hs sudy, was no possble o deermne he ncrease rao n he operaonal producvy of he corporaon because WLC has been payng conracors for coal packagng process snce 2004, here was no enough relable daa a he me of hs sudy, and here was no a eam of researchers capable of conducng a comprehensve sudy on hs ssue. However, when we compare he cos of hrng conracors for he coal packagng process o he cos of esablshng a fully auomaed coal packagng sysem, and we consder he posve effec of he fully auomaed verson, we can clearly sugges ha he proposed fully auomaed sysem wll make a posve conrbuon o he operaonal producvy of he enre corporaon. Table 6. Daa for he fully auomaed coal packagng sysem esmaed for 2012 DMU Daa for The Fully Auomaed Coal Packagng Sysem Quany of Bagged Coal Produced (ons) Quany of Coal Fed (ons) Number of Workers (no/days) Amoun of Energy (kwh) January February March Aprl May June July Augus Sepember Ocober November December MEAN Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül 2018

13 January February March Aprl May June July Augus Sepember Ocober Nonember December Malmqus-TFP Change 0,826 0,847 0,806 0,820 0,870 0,885 0,870 0,870 0,806 0,800 0,826 0,840 Mehme Nur BAHŞİŞ, Yaşar KASAP Fully Auomaed Baggng Sysem The Curren Baggng Sysem 1,000 0,800 0,600 0,400 0,200 0,000 Monhs Fgure 4. Effcency comparson of he curren coal packagng un and he fully auomaed coal packagng sysem for he year CONCLUSION AND RECOMMENDATIONS In order o be able o run he companes n he mnng secor wh modern facles, low cos and hgh effcency, exsng operaonal processes mus be auomaed professonally and he echnology used mus respond o he hghes sandards. Consderng he fac ha every secor needs labor wh pecular qualfcaons, parcularly he declne n lgne mnng has a negave mpac on he raned and experenced work force demanded by he mnng secor. The WLC coal packagng plan has been producng bagged coal snce he 2000s. Currenly he plan, whch was desgned accordng o he echnology back hen, requres oo much labor and he plan consumes oo much energy because s requred o be runnng even when here s no producon. Also, here are nevable producon losses because he plan canno have enough qualfed workers when necessary as a resul of hrng workers dependng on he demand for coal n ceran perods. An effcen saff polcy and dealng wh he problems of he saff effcenly would play a key role n ncreasng he producvy of he plan. However, seems currenly unlkely o develop an effcen saff polcy as he coal packagng plan does no hre a consan number of workers, workers are hred dependng on he need a a specfc me, and here s no suffcen qualfed labor n general. The producon capacy of he curren WLC packagng plan s 6000 ons/day. On he oher hand, an analyss of daa regardng he perod beween he years 2006 and 2012 reveals ha he coal packagng uns have never operaed a full capacy due o nsuffcen qualfed labor force. The sudy found ha he maxmum possble quany of producon would be 4700 ons/day provded ha he packagng uns were run 24 hours a day wh all of her equpmen. Ths value ndcaes ha he plan operaes approxmaely a 75% producvy. In fac, 28 conveyor bels, hree vbrang screens, and hree roll crushers are acve even when here s no producon. Also, her deprecaon expenses should be aken no consderaon as well as he energy hey consume. Ths sudy nvesgaed he producvy changes due o he converson of he curren coal packagng Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül

14 Effec of Auomaon on he Producvy of a Coal Packagng Plan plan no a fully auomaed packagng sysem wh respec o he posve effecs of auomaon on producvy. The analyses were carred ou under he assumpon ha he number of workers o be hred n he fully auomaed packagng sysem wll be consan every year and n every monh of he year, energy wll be consumed as long as here s a packagng process ongong, and he sysem wll be free of producon losses. The resuls revealed ha whle he fully auomaed packagng plan would acheve full effcency (100%), he average effcency of he curren packagng plan was 83.9%. The producvy score of he plan, and of he enre corporaon herefore, s expeced o be hgh consderng he fac ha here wll no be any varaon n he number of workers, less energy wll be consumed, and here wll no be any producon losses n hs sysem. More comprehensve research s needed o be able o clearly denfy he ncrease rao n he operaonal producvy of he corporaon. Fuure sudes o be conduced by approprae eams of researchers can accuraely collec daa abou each of he uns of he corporaon and defnely deermne he effec of a fully auomaed coal packagng plan on he operaonal producvy of he enre corporaon. 5. ACKNOWLEDGEMENT We would lke o acknowledge Wesern Lgnes Corporaon Drecory for her nvaluable suppor for hs sudy. 6. REFERENCES 1. CMEKS Endüsryel Konrol Ssemler San. Ve Tc. Ld. Ş., Oomasyon Nedr?, , Alexander, JR., Producvy Through Auomaon, Telemacs and Informacs, Huchnson G., Nalk B., Pflughoef K., Producvy of Programmable Auomaon A Smulaon-Based Analyss of a Roboc Sysem for Componen Inseron, Journal of Manufacurng Sysems, Rosenfeld, Y., Shapra, A., Auomaon of Exsng Tower Cranes: Economc and Technologcal Feasbly, Auomaon n Consrucon, Pullg, J., Maxham G., Joseph F., Har, JR., Salesforce Auomaon Sysems an Exploraory Examnaon of Organzaonal Facors Assocaed wh Effecve Implemenaon and Salesforce Producvy, Journal of Busness Research, Surrey, J., Techncal Change and Producvy Growh n he Brsh Coal Indusry, , Technovaon. 12(1), Plessmann, K.W., Dlckhaus B., Schey S., A Sysem for he Auomaon of Mnng Machnes, Conrol Eng. Pracce, 1(3), Couch, G Coal Preparaon-Auomaon and Conrol, Fuel and Energy Absracs, 37(3), (1) 9. Jamsa-Jounela, S.L., Curren Saus and Fuure Trends n he Auomaon of Mneral and Meal Processng, Conrol Engneerng Pracc, Feng Q., Chen H., The Safey-level Gap Beween Chna and he US n Vew of he Ineracon Beween Coal Producon and Safey Managemen, Safey Scence, Kızıl, M.S., Kızıl, G., Taar, Ç., Köse, H., Madenclke İler Teknolonn Kullanımı, Madenclk, Maden Mühendsler Odası. 12. Farrel, M.J., The Measuremen of Producvy Effcency, Journal of The Royal Sascal Socey, 120, Charnes, A., Cooper, W., Rhodes, E., Measurng he Effcency of Decson Makng Uns European Journal of Operaonal Research, 2(6), Munz, M.A., Separang Manageral Ineffcency and Exernal Condons n Daa Envelopmen Analyss, European Journal of Operaonal Research, 143, Kasap, Y., Türkye Kömür Madenclğnde Eknlk ve Vermllk Gelşm: Ver Zarflama Analz. 174 Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül 2018

15 Mehme Nur BAHŞİŞ, Yaşar KASAP 16. Coell, T.J., Rao, D.S.P., G.E., Baese, An Inroducon o Effcency and Producvy Analyss, Kluwer, Boson, hp://books.google.com. 17. Grfell, T., Lovell, C.A.K, A Noe on he Malmqus Producvy Index, Economcs Leers, 47, Färe, R., Grosskopf, S., Lovell, C.A.K Producon Froners. New York and Cambrdge: Cambrdge Unversy Press. 19. Mahadevan, R., A DEA Approach o Undersandng he Producvy Growh of Malaysa s Manufacurng Indusres, Asa Pacfc Journal of Managemen, 19, IMECO, Elecronc Twn Weghng Hopper Process Wegher, Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül

16 Effec of Auomaon on he Producvy of a Coal Packagng Plan 176 Ç.Ü. Müh. Mm. Fak. Dergs, 33(3), Eylül 2018