ECO Operator Training from Caterpillar

The training is applicable to excavators, wheel loaders, off highway trucks, articulated dump trucks, dozers and track-type tractors, and can result in lower fuel consumption and less harmful emissions into the environment.
To validate the benefit of the training, CIVT conducted two case studies using wheel loaders. The case studies were conducted under conditions that replicate working machine operation, using the loading process of a haul truck. Three bucket passes were recorded for each operator, and using Caterpillar ET software, cycle time and engine data were taken from the first bucket load to the last bucket. After that, the theory training that aims to refine operator skills and eliminate bad techniques was taught. This was closely followed by the operator performing the same loading process as before with their new skills to enable measurable data comparisons to be made.

Table 1
The data gathered from CIVT’s Caterpillar® ECO Operator Training case studies indicate significant cost savings in fuel consumption.
 

The benefit of ECO training isn’t just in reduced fuel consumption; it also improves engine life, servicing costs, safety and reduces carbon footprint.
The Carbon Pollution Reduction Scheme (CPRS) to be implemented from July 2011 will mean that reducing fuel usage and an operation’s carbon footprint will be necessary. In the government’s Summary of Policy Decisions document it states that ‘…the coal sector is unlike any other sector with respect to the diversity of the emission profiles between mines. Some coal mines have very high fugitive emissions.’
Part of this diversity (apart from output) could be attributed to the varying skill levels between operators. Investing capital in training existing staff could reduce operating costs under an emissions trading scheme.
While the case sAftertudies conducted by CIVT do not represent the average daily operation of a machine, the case studies are evidence of refined operation techniques and a new understanding of the measurable difference an operator can make.
The financial significance of the data average fuel reduction of 3.56 per cent becomes serious when applied to a mine site. Table Two shows the potential savings based on the case studies, with reductions at 8.92 per cent, 6 per cent and 5 per cent respectively.
In order to confirm the transfer of the skills to the actual work place, CIVT also collected data in the workplace of at least one operator from each of the case studies.

Table 2.
Based on its case study data, CIVT has estimated the cost savings that could be achieved in a year, assuming 10 hours operating days, a five-day working week and a 52-week working year, using a typical Caterpillar 980G or 980H wheel loader.

The Caterpillar Institute website now has a fuel savings calculator, which asks for information on current fuel consumption and instantly calculates estimated annual fuel saving in litres, dollars and carbon reduction. For more information visit: www.caterpillarinstitute.com.au/site/index.asp

* The Caterpillar Institute (CIVT) is a Registered Training Organisations that has been established as a joint venture between Caterpillar and William Adams Pty Ltd. CIVT provides technical, operator and safety training and assessment services to the mining industry.