Safety Risk Model Trackless Mobile Mining Machinery Operation

“Safety Risk Model Trackless Mobile Mining Machinery Operation for South African Open Pit/Cast Operations An Industry wide perspective

Open Cast/Pit MOSH

Purpose The model is a corner stone for the MOSH initiative’s process to identify Leading Practices with the potential to make the biggest contribution to industry wide Safety performance for trackless mobile mining machinery operation

Level One: Overall Model Equipment • Body and organ vibration • Hand feet injuries • All ranges of body injuries Nature of Exposure Operator Information Short term outcomes Nature of the Hazard Exposures • Injury • Disability • Death • Production loss • Sec 54 • Sec 52 Outcomes of the exposure Exposed persons Environment Machine Operators • Maintenance Technicians • Workers/Pedestrians • Equipment operation Long term outcomes • Injury • Disability • Death • Lower ROI • Increased regulation • Compensation

Level two: Sources of Equipment Hazards Difficult/poor access for operators Difficult/poor access for Persons working on Vehicle Level three: Causes of Equipment Hazards OEM Nip point on machines • Inadequate definition of use/poor understanding of use. Poor Ergonomics/HF of Machines Fatigue failure of safety related components • Inadequate field testing of equipment/components • Inadequate risk analysis for specific requirements • OEM design process inadequate • Inadequate user field feedback Inadequate provision For Visibility Inadequate Safety Systems Design Equipment Poor reliability of Safety Systems Equipment failure Machine fires Poor Maintainability/ maintenance access Poor provision of Safety Systems by OEMs systems • Lack of safety engineering competence • Inadequate operability and maintainability analysis • Poor/no Human factors engineering • Inadequate design specifications Company • Lack of user acceptance testing of new equipment designs • Inadequate user requirements specifications

Level two: Sources of Operator Hazards • Machine Vibration • Lack of sleep • Shift patters • Distance from work • Repetitive work • Poor discipline wrt medical • Substance abuse • Social conditions • Poor physical condition • Poor mental condition • Poor understanding of importance of training • Inexperience with training design • Cost of effective training programmes • Difficulty to measure training effectiveness Operator • Overly elaborate Fatigue check list • Checklist/Literacy level mismatch • Checklist not risk based • Production pressure Pre use • Complacency inspection • No review of checklists • High risk tolerance • Cultural • National • Social • Lack of understanding cause & effect Not using / wrong use of PPE • Inappropriate PPE • Ineffective PPE • Poor safety culture • Double standards • Familiarity • Poor safety culture Operator complacency Inadequate training Operator • Old drivers • No test of risk Comprehension Dangerous Operating of machine • Inadequate driver training and experience • Production pressure • Poor risk comprehension • Over confidence/familiarity • Lack of emergency experience • Poor Safety Culture Man / Machine misfit Inadequate competency assessment –no emergency simulation Poor Safety Culture Poor Literacy/ risk comprehension Level three: Causes of Operator Hazards Bridging safety devices Poor fitness For work • Poor eye sight • Physically unfit • Medication impact • Poor Health • Poor selection criteria (Ergonomic review) • Historic selection • New model machines old operators • Poor understanding of importance • Inexperience with design of competence assessment • Challenges to measure • Risk to simulate • Cost to simulate • Nuisance alarms • Poor reliability • Poor safety culture • Sabotage • perceived production impact

Level two: Sources of Equipment Operation Hazards Level three: • Inadequate understanding of fully functioning equipment and safety relationship • Inadequate understanding of leading practices in traffic management • Traffic management not fundamental mine design focus Inadequate • Poor safety culture traffic • Inadequate understanding management of full functioning equipment and safety relationship Lack of • Capital cost constraints maintenance infrastructure • Operating procedures evolved over many years • No physical verification of operating procedures • Office based procedure review • Composition of review teams • Poor safety culture from management • Road surface maintenance not considered as critical for safety Sub-standard and unpractical operating procedures Poor roadssurface and gradient maintenance Poor equipment health standards Inadequate mine design/layout/ mine capacity changes Safety controls too low on hierarchy of controls Equipment operation Mismatch of operating procedures and mine design. Roads-surface and gradient standards are inadequate Causes of Equipment Operation Hazards Insufficient Recovery Standards and equipment • Standards not established for specific environmental conditions • Standards not established for specific equipment characteristics • Non systemic approach to mine design changes • Safety impact assessments not always done • Temporary vs Permanent • Production only considerations • Inadequate awareness of new and leading practices • Poor continuous improvement process • Capital constraints • Reviews after incidents inadequate • Poor management of mine design changes • New operating procedures not considered and/or not practically verified before issuing • Copy and paste of procedures

Level two: Sources of Information Hazards Inadequate/no operator communication systems Lack of/late ground stability information Poor spotter signals . Information Lack off/late incident information Level three: Causes of Information Hazards Failure of GPS systems Late/incomplete roads -surface and gradient condition information • Information or the lack thereof is not generally viewed as a source of hazards • Risk of no/poor information not formally assessed

Level two: Sources of Environmental Hazards Sudden Flooding Level three: Causes of Environmental Hazards Fall of Ground Lightning Environment Rain Dust