Improving Excavator Productivity and Loading-Hauling Efficiency Through Double Side Loading in Open-Pit Mining Operations

Abstract

Open-pit mining operations require efficient loading and hauling systems to achieve production targets while minimizing operational delays and equipment idle time. Conventional Single Side Loading systems often result in high queuing time, hanging time, and cycle time, which reduce excavator productivity and overall operational efficiency. This study evaluates the effectiveness of Double Side Loading (DSL) implementation in improving excavator productivity and loading-hauling performance in an open-pit mining operation in East Kalimantan, Indonesia. A quantitative before-and-after operational analysis was conducted using actual field data collected from 250-ton and 300-ton excavator fleets, comprising more than 1,000 observed loading cycles. The analyzed parameters included excavator productivity, queuing time, hanging time, cycle time, and match factor. Descriptive statistical analysis and paired sample t-tests were employed to assess the significance of operational changes following DSL implementation. The results indicate that DSL significantly improved excavator productivity by 20% for the 250-ton fleet and 17% for the 300-ton fleet. Queuing time decreased by 25% and 29%, while hanging time was reduced by 34% and 26% for the 250-ton and 300-ton fleets, respectively. In addition, cycle time decreased by 12.46% and 13.04%, whereas match factor improved from 0.96 to 1.00 and from 0.98 to 1.02. Statistical testing further confirmed the significance of the observed improvements. The paired sample t-test indicated significant productivity gains for both excavator fleets, with the 250-ton fleet yielding a t-value of 4.12 and a 95% confidence interval of 124.5–211.5 BCM/h, while the 300-ton fleet yielded a t-value of 3.89 and a 95% confidence interval of 145.2–256.8 BCM/h.