How On-Board Weighing Systems Increase Quarry Productivity

Aggregate producers are quickly recognising the benefits of on-board weighing systems, not only to improve payload data, but to also enhance all aspects of the production workflow.

On-board weighing systems can improve operational efficiency and drive more cost-effective operations, right the way through from face to plant to customer.

Productivity measurements

This is just three ways in which on-board weighing systems can increase productivity in quarries.

Tonnes moved per hour

In quarries, measuring cycle times & truck loads per hour is a common way to measure productivity. Trucks filled to 100% capacity move more material quicker and therefore costs less because under utilised payload is eliminated, production is improved and revenue increases.

When evaluating tonnes moved per hour, it’s important to consider that just because a truck is taking more loads per hour, there may not necessarily be an increase in the total number of tonnes moved per shift. In addition, loading more tonnes per truck does not necessarily improve production. Studies suggest this may be because trucks carrying more than optimal load weights also have an impact on machine utilisation, machine repairs, fuel efficiency and overall operating costs.

On-board weighing systems also eliminate the need to transport consignments to loading bays or weighing stations, meaning the entire process is more efficient and the number of man-hours required is minimised. They also offer real time data of machines and material movement, meaning vehicle operators can make adjustments to affect production during the shift.

Loadout efficiency

Competitive businesses in quarrying are continually focusing on optimising truck utilisation and maximising loadout efficiency.

Hauling aggregate is most profitable when haul trucks are loaded to 100% capacity. When there are under-loaded trucks, or truck delays, and fewer tonnes of aggregate is moved per day, revenue is lost. Similarly, when trucks are overloaded, there is a risk of excessive wear of machinery and an increase in the risk of accidents.

The aim for most aggregate businesses is to load trucks quickly and accurately to maximise loadout efficiency and ensure the correct load amount is transported. An on-board weighing system that can store and analyse data based on machine, product, date, time, customer or any other combination of parameters will drastically aid workflow and improve margins.

Cycle time analysis

On-board weighing systems can measure the cycle times of each loading event throughout the entire workflow. This enables organisations to analyse the data and determine how efficiently aggregate is moving throughout each process.

Real time information from on-board scales can show time spent queuing to load, loading, hauling, haul stoppage, queuing to dump, dumping, return and return stoppage. By assessing the data from each haul truck, site managers and operators can pinpoint the weakness in the workflow and any underlying causes of delays, which could be anything from bottleneck queues to damaged or wet haul roads.

In addition, the latest data management packages allow stock piles to be geo-fenced for auto product recognition and track & trace stock movement for example, to and from product bays feeding an asphalt plant. With over 75 years of industry experience, our knowledgeable team at RDS MME can work with you to improve accuracy and efficiency within your business by helping you to incorporate the best in on-board weighing technology. Please contact us to find out more.