Training Module

on

HRD Centre, RMD

Kiriburu
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Pledge

As a member of SAIL, RMD team, I strongly believe that the well

being of myself and my family is solely dependent on the

prosperity of SAIL. I therefore pledge that every job I do

will be a quality job resulting in full satisfaction of my internal

customers and contributing to the higher profitability of the

company. I shall constantly strive to upgrade the skill and

competence of myself and that of my subordinates to improve

performance and I will take pride in contributing my best towards

the common goal of the company. I shall utilise all the available

resources innovatively in bringing about cost effectiveness and

reduction in waste and undue expenses. I shall follow all the

rules and regulations of the company and shall always be fair

and respectful in dealing with others to make effective team

working.

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Acknowledgment
It is a matter of great pleasure & pride to put on record our sincere gratitude to
Shri. P.P. Chanana, ED (OPRN) in having confidence in us & expressing his
desire for having a training module on dumper tyres for RMD Mines. We are
also thankful to him for giving necessary guidelines.

We also put on records our sincere thanks to Shri G.K. Sinha E.D. (Maint.) for
sparing his time for encouragement & guidance.

We take pride in putting on record our gratitude to Shri R.S.L Agrawal, GM,
Kiriburu - Meghahatuburu Iron Ore Mines Complex , for his encouragement &
guidance .

We are grateful to Shri S. D. Tyagaraj , Ex. Addl. Director MTI & GM (P&A)
RMD, for his guidance and encouragement.

We are also grateful to Shri P.V.S. Sarma, Addl. Director, MTI.

We put on record our sincere thanks to Shri V. B. Pandey, DGM (Safety), for his
encouragement .

We are also thankful to Shri H.S. Prasad, DGM, Meghahatuburu.

We are also thankful to Shri M.K. Bindu , AGM I/C , Kiriburu for his guidance
& help given to us .

We are grateful to Shri A. K. Varma , Sr. Manager (Mech.) for his constant help &
guidance for preparation of this module.

Our sincere thanks are due to Shri Rajashekhar Sr. Mgr.(Mech.) & Shri P. N. Singh
Sr. Mgr.(Mech.) and Shri V. K. Singh, AM (Mech.) MIOM for their help.

Our sincere thanks are due to Shri T. Patnaik, AM (Mech.) KIOM for his help.

We are thankful to Dr. B. M. Tiwari, Jr. Exe.(Hindi) for the Hindi translation work
and to shri. A.M. Khan, Steno and to other colleagues at HRD Centre, RMD,
Kiriburu for their contribution.

(A. R. Shere)
Sr. Mgr. ( Mining)

Place : Kiriburu (Atanu Mukherjee)

Date : Asst. Mgr. , (HRD)
Preface

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It was found that there is considerable difference in dumper tyre life in different
RMD Mines , implying that optimum tyre life is not obtained in the RMD
Mines. This indicated that RMD is incurring heavy losses due to less tyre life . To
make RMD Mines competitive in today’s business scenario, we felt to contribute
something ( however little it may be) and hence this training module on dumper
tyres.

The programme aim , objectives , structure , target population etc. are presented in
this humble training module effort.

Systematic approach to training (SATT) has been followed while designing this
training module and hence we are confident that this module of immense help to
gain proper insight to programme Coordinator and faculty for maintaining
uniformity and quality. Adherence to the programme schedule will ensure benefit
to the company through improvement in dumper tyre life & cost reduction .

(A. R. Shere)
Sr. Mgr. ( Mining)

(Atanu Mukherjee)

Place : Kiriburu Asst. Manager (HRD)

Date:

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Contents
1. Introduction

2. Analysis of Problem

3. Identifying solutions to the problem

4. Organisational Need

5. Criticality of the Problem

6. Target Population

7. Identification of Training Needs

8. Aim of the Training Programme.

9. Training programme structure

10. Contents of the sessions

11. Evaluation and feedback

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Introduction

During one of the Heads of Maintenance meeting held at HRD Centre, RMD,
Kiriburu, it was revealed that dumper tyre life in RMD Mines varies from
3000 hrs. to 6000 hrs. Such wide variation indicated absence of standard
operation, maintenance & storage practices for dumper tyres in RMD
Mines. It also indicated that if proper training is imparted to concerned
persons RMD could save a lot through improving dumper tyre life. This
focussed on the need to have a well developed training module on dumper
tyres.

‘Systematic approach to training’ technique has been used to develop this training
module. While developing the training module need to cover all aspects
which influence dumper tyre life have been considered.

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Analysis of the Problem

Findings from the discussion with the Engineers, Supervisors and workers & field
observations are as follows :

1. Absence of regular practice for checking tyre inflation

2. Improper operation practices of dumper operators resulting in reduced tyre life.

3. Improper configuration of haul roads & insufficient haul road maintenance.

4. Overloading of dumpers.

5. Absence of standard maintenance practice for

i) Adjusting the alignment of steering wheels
ii) Brake adjustment

6. In many dumpers rock ejectors have been removed.

7. Absence of tyre rotation practice

8. Absence of practice for maintaining tyre records.

9. Improper tyre storage practices.

Identifying Solution to the Problem

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After analysing the findings the following training solutions have been identified .

1. Technical knowledge about tyre structural parts & their functional aspects and
knowledge about factors affecting dumper tyre life.

2. Knowledge about how to maintain proper inflation pressure.

3. Knowledge about proper dumper operating practice and care for maintaining
good haul roads.

4. Knowledge about dumper tyre maintenance & storage practices and techniques
in tyre handling & tyre fitting.

5. Knowledge about Dumper maintenance aspects which affect dumper tyre life.

6. Knowledge about maintenance of tyre records & history sheets.

7. Awareness about cost implications of dumper tyre life.

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Organisational Need

Dumper tyre life in RMD Mines varies from 3000 hrs. to 6000 hrs. Also there
have been instances where for want of tyre, dumpers have remained under break
down thus reducing the operational fleet of dumpers. To improve the productivity
of the mines & reduce cost through improving dumper tyre life has become our
organisational need.

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Criticality of the project

In the present business environment Cost Control / reduction has become key to
success. Optimum utilisation of available resources is essential for cost reduction /
control. Dumper tyres is one such item which not only affect costs but also the
availability of dumpers.

With reduced dumper availability not only the production but also quality &
developmental activity gets adversely affected. Any adverse effect on production,
quality & development activity is bound to have adverse effect on profitability of
mine & in turn of RMD. Improvement in dumper tyre life is bound to reduce
cost & in turn will improve profitability in mine & RMD.

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Target population

Dumper tyre life depends on operation & Maintenance of dumper, storage of

tyres, haul road & mine face conditions. Hence target population should cover
dumper operators, mining supervisors, mechanics, tyre fitters & tyre storage
personnel.

Since this module has been designed for improving dumper tyre life & cost
reduction in RMD Mines, target population will cover above mentioned personnel
from above mentioned areas from mechanised mines of RMD.

Identification of Training Needs

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The problem was discussed in various meetings & with concerned officers in
detail. The need for a training, complete in all respect, was expressed during
discussion. Also need to include all the concerned persons who can contribute in
improving dumper tyre life for training was also expressed strongly. Hence all
the knowledge & skill needs are to be covered in the training module. As far as
attitudinal needs are concerned instead of separate session they will be dealt in
sessions which exclude technical aspects. Following are the identified training
needs :

Individual Training Needs:

Knowledge :
Lack of understanding in :
 Dumper tyre structural parts & their functional aspects.
 Factors affecting dumper tyre life
 Cares to improve dumper tyre life
 Usefulness of maintaining dumper tyre record & history sheets
 Loss due to damage in tyre life

Skills:
Lack of skill in :
 Dumper tyre maintenance & storage
 Maintenance of dumper concerning mechanical irregularities affecting dumper
tyre life.
 Tyre handling & tyre fitting.
 Proper operation of dumper with due attention for improving dumper tyre life
 Checking & maintaining proper inflation pressure.

Attitude:
Lack of attitude in :
 Disciplined approach for pre-start checks & operational practice
 Keen observation for haul road conditions.
 Housekeeping & cleanliness
 Disciplined & systematic approach for tyre status report, tyre records &
history sheets.
 Teamwork attitude.
 Cost consciousness for improving dumper tyre life

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Aim of the Training Programme

Aim of the Programme :

The aim of the training programme is to enhance competence i.e. knowledge &
skills of the personnel to reduce damage to the dumper tyre, to take care in
storage, handling for improving dumper tyre life, to maintain tyre records &
history sheets for utilising the same for improving tyre life and reducing cost.

Behavioural Objectives

Knowledge :
On completion of training, the participants will have acquired the understanding to
:
 Dumper tyre structural parts & functional aspects.
 Factors affecting dumper tyre life
 Cares to improve dumper tyre life
 Usefulness of maintaining dumper tyre record & history sheets
 Loss due to damage to tyres and reduced tyre life.

Skills:
On completion of training, the participants will be able to :
 Carry out proper dumper tyre maintenance
 Store the tyre with proper care
 Carry out maintenance of dumper concerning mechanical irregularities affecting
dumper tyre life.
 Handle and fit tyre with required precautions regarding safety and tyre health.
 Operate the dumper with proper attention for improving dumper tyre life
 Check & maintain proper inflation pressure.
 Maintain tyre records.

Attitude:
On completion of training, the participants will have desire to improve :
Approach for pre-start checks & operational practice
 Observation for haul road conditions.
 Housekeeping & cleanliness
 To maintain discipline & have systematic approach for tyre status report, tyre
records & history sheets.
 Teamwork.
Dumper tyre life to reduce cost and improve profitability

Training Programme structure

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The duration of training programme will one full day and classroom training will be
imparted. As the group is heterogeneous, skill improvement for tyre handling and
fitting has been attempted through audio visual means.

Training Methodology

The process of learning will be through :

 Lectures
 Discussion
 Interaction- Question - Answers
 Audio –visuals

List of Faculty :

 Shri A. R. Shere,
Sr. Manager (Min), HRD Centre, RMD, Kiriburu.
 Shri T. Patnaik
Asst. Mgr. (Mech.), Kiriburu.
 Shri Atanu Mukherjee.
Asst. Mgr. (HRD), HRD Centre, RMD, Kiriburu.
 Shri S. Singh.
Asst. Mgr. (P&A), Meghahatuburu.
 Shri V.K. Singh.
Asst. Mgr. (Mech.), Meghahatuburu.

Facilities Required :
 O.H.P
 Flip Chart.
 TV
 VCR

Programme Coordinator :
 Shri Atanu Mukherjee, Asst. Mgr. (HRD), HRD Centre, Kiriburu.

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Programme Structure

Programme Tittle : Dumper Tyres

Duration : 1 Day

Time Session Faculty

S/Shri.

9.00 - 9.30 AM Ice Breaking A Mukherjee /

A R Shere

9.30 - 10.30 AM SAIL Today & Cost Control, S Singh

Losses due to damage to the tyres &
reduced tyre life

10.45 –11.30 AM Dumper Tyre – Structural Parts & their T. Patnaik

functional aspects

11.30– 1.00 PM Dumper Tyre life A Mukherjee /

A R Shere

2.00 – 3.30 PM Dumper Tyre Maintenance & Storage T. Patnaik

Tyre Record & History sheet

3.45 – 4.30 PM Tyre Handling & Tyre fitting T. Patnaik

4.30 - 5.00 PM Review , Feedback & Valediction A R Shere

Tea Break : 10.30 AM to 10.45 AM

3.30 PM to 3.45 PM
Lunch : 1.00 PM to 2.00 PM

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Sessions contents

Session 1 : Ice Breaking

Session Objectives :
At the end of this session, the participants will be able to :

• Appreciate the necessity and importance of the total programme for

better performance .
• Get to know each other personally

Session Content :
• Inauguration
• Information about different sessions of the programme

Methodology :

• Lecture
• Interaction & Question - Answers

Facilities Required :

• OHP
• White Board
• Flip Chart

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Session 2 : SAIL Today and Cost Control, Losses due

to damage to tyres & reduced tyre life.

Session Objectives :
At the end of this session , the participants will be able to :

• Appreciate the cost control measures .

• Know the present market scenario .
• Know how tyre health & life affect the cost of production

Session Content :

• Present market scenario

• Competition
• Cost Control measures
• Cost saving measures in individual areas
• Dumper tyre life
• Cost of dumper tyres & cost saving through increasing dumper tyre
life and reducing damage to tyres.

Methodology :

• Lecture
• Interaction & Question – Answers
• Discussion

Facilities Required :

• OHP
• White Board
• Flip Chart

Session 3: Dumper Tyre – Structural Parts & their

functional aspects

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Session Objectives :
At the end of this session , the participants will be able to :

• Know the dumper tyre specifications .

• Understand the different structural parts & their function .

Session Content :
• Dumper tyre specifications
• Different structural parts & their function
Rim
Chafers
Side wall
Shoulder
Tread
Plies

Methodology :

• Lecture
• Interaction & Question – Answers
• Discussion

Facilities Required :

• OHP
• White Board
• Flip Chart

Session 4: Dumper Tyre Life

Session Objectives :
At the end of this session , the participants will be able to :

• Know the various factors

influencing dumper tyre life .

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• Know about precautions

to be taken against damaging of tyre life.

Session Content :
• Inflation Pressure - Effect of over inflation , under inflation &
correct inflation .
• Ill effects of bleeding
• Tyre loading - ill effects of uneven loading
• Speed and length of haul – heating effect & wear .
• Operating Practices & Haul Road conditions
• Daily inspection & checks .

Methodology :

• Lecture
• Interaction & Question – Answers
• Discussion

Facilities Required :

• OHP
• White Board
• Flip Chart

Session 5 : Dumper Tyre Maintenance & Storage,

Tyre Record & History sheet

Session Objectives :
At the end of this session , the participants will be able to :

• Know the various

maintenance aspects

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• Appreciate the practice

for storage of tyres

Session Content :
Maintenance Aspects
• Alignment of steering wheels
• Brake adjustments
• Twin fitment - Dual tyre matching
• Rock Ejector
• Tyre rotation
• Prompt repair of injured tyres
• Mechanical irregularities / misalignments
Misalignment of front wheels
Toe in & toe out & feather effect .
Brake drums
Improperly adjusted brakes .
• Rims & wheels
• Tyre retreading

Tyre storage aspects

• Storing Place - Cleanliness , Effects of light , air & dust , temperature ,
humidity.
• Storing Practices
• Stacking method
• Ill effects of piling
• Effects of tyre mixing in stacking
• Storing tubeless tyres
• Inspection before storing .

Tyre records & History sheet

• Uses for history sheet
• Cost calculation
• Tyre performance
• Analysis for dumper wise use
Methodology :
• Lecture
• Interaction & Question – Answers
• Discussion

Facilities Required :
• OHP
• White Board
• Flip Chart

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Session 6 : Tyre Handling & Tyre fitting

Session Objectives :
At the end of this session , the participants will be able to :

• Know how to handle the

tyres
• Understand the SOP of
tyre fitting

Session Content :
Tyre Handling
• How to dissemble tyre.
• Discussion on wrong practices & how to eliminate them
• Film on Tyre Handler

Tyre fitting
• How to assemble tyre
• Safety aspects .
• SOP for tyre fitting

Methodology :

• Lecture
• Interaction & Question – Answers
• Discussion
• Audio visual

Facilities Required :

• OHP
• White Board
• Flip Chart
• VCP
• TV

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Session 7 : Review , Feedback & Valediction

Session Objectives :
At the end of this session , the participants will be able to :

• Evaluate themselves of their own progress in terms of knowledge .

Session Content :
• Discussion covering all aspects
• Documentation

Methodology :
• Lecture
• Interaction & Question – Answers
• Discussion

Facilities Required :
• White Board
• Flip Chart

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Evaluation and Feedback

Evaluation & Feedback Procedure :

The effectiveness of the training programme will be evaluated in three levels :

 Reaction level : In the last session of the programme , feedback through

discussion will be taken to evaluate the effectiveness of the training
programme.

 Behavioural Level : Through interaction with officers , supervisors feedback

will be taken, after about 3 months after conduction of the training
programme.

 Result level : After the training of target population , statistical comparison

will be made.

Programme Evaluation

Feedback Form :
In the last session of the training , effectiveness of the training will be assessed
using Feedback Form (Ref : Annexure ) where participants will give their
reactions about fulfillment of needs, content of the programme, process of the
programme etc. by grading in 1 to 5 point scale.

The analysis of this feedback will include % fulfillment of the needs and will
also give guidance with respect to course correction / modification in the training
programme.

Behavioural Level :
Through interaction with officers and supervisors , Feedback will be taken about
the Behavioural changes and performance changes of the trained persons, to
assess permanency about changes behavioral pattern and skill level of the
participants. The feedback is to be taken after the lapse of 3 month period after
conducting the programme.

Result level :
This will be carried out after the target population is trained. From breakdown
analysis and dumper tyre life analysis , comparisons will be made with past record
to assess effectiveness of the programme.
This result will indicate fulfillment of organisational need in terms of improved
dumper tyre life.

Feedback Form

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(To be filled in by participant)

Name of the Programme : Dumper Tyres

Venue :

Sl. Elements Poor Satisf- Aver Good Exce Score

No actory age. llent
. 1 2 3 4 5
1 Knowledge about losses due to
reduced dumper tyre life
2 Knowledge About Dumper tyre
structural parts and their functions.
3 Knowledge about different factors
affecting dumper tyre life
4 Knowledge about Dumper maintenance
factors to improve dumper tyre life
5 Knowledge about precautions to be
taken to improve tyre life while
operating the dumper.
6 Knowledge about necessity &
importance of pre-start and post
operation checks
7 Knowledge about how to report duper
tyre status and usefulness of
maintaining dumper tyre records and
history sheets
8 Knowledge about proper storing of
tyres
9 Knowledge about mechanical
irregularities affecting dumper tyre life
10 Knowledge about how to handle and
fit tyre and safety precautions while
handling tyres
11 Knowledge about checking and
maintaining proper inflation pressure.
12 Knowledge about importance of
housekeeping & cleanliness

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Suggestions, if any :

A. ----------------------------------------------------------------------------------
------------------------------------------------------------------------------
----
------------------------------------------------------------------------------
----
B. ----------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
------------------------------------------------------------------------------
C. ----------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
------------------------------------------------------------------------------

(Optional)

Name :
Designation :
Staff No. :
Department :
Mine :
Signature

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Feedback Form
(To be filled in by Mining - Line managers / Supervisors)

Name of the Programme : Dumper Tyres

Venue :

Sl. Elements Improvement

No.
Very Little Some Good Excellent
little
1 What is the improvement in carrying
out Prestart checks & Post operation
checks.
2 What is the improvement in
maintenance of proper inflation
pressure
3 What is the improvement in
reduction in overspeeding of dumpers
4 What is the improvement in
avoidance of overloading of the
dumpers
5 What is the improvement in
placement of dumper in shovel to
avoid uneven loading
6 What is the improvement in stoppage
of maloperation of dumper
7 What is the improvement in use of
retarder for controlling speed
8 What is the improvement in water
sprinkling practice

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Suggestions / Comments if any :

A. ----------------------------------------------------------------------------------
------------------------------------------------------------------------------
----
------------------------------------------------------------------------------
----
B. --------------------------------------------------------------------------------------
------------------------------------------------------------------------------
----------------------------------------------------------------------------------
C. ----------------------------------------------------------------------------------
----------------------------------------------------------------------------------
----------------------------------------------------------------------------------

(Optional)

Name :
Designation :
Staff No. :
Department :
Mine :
Signature

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Feedback Form
(To be filled in by Mechanical Services - Line managers / Supervisors)

Name of the Programme : Dumper Tyres

Venue :

Sl. Elements Improvement

No.
Very Little Some Good Excellent
little
1 What is the improvement in
maintaining proper tyre records ?
history sheet
2 What is the improvement in
checking /maintenance of proper
inflation pressure
3 What is the improvement in handling
and fitting of tyres
4 What is the improvement in
participant’s concern about alignment
of steering wheels
5 What is the improvement in
participant’s concern about brake
adjustments
6 What is the improvement in
participant’s concern about dual tyre
matching
7 What is the improvement in
participant’s concern about
functioning / free movement of Rock
ejector
8 What is the improvement in
participant’s concern about rims &
wheel condition
9 What is the improvement in
participant’s concern about timely
tyre retreading
8 What is the improvement in
participant’s concern about toe in &
toe out

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Suggestions / Comments if any :

A. ----------------------------------------------------------------------------------
------------------------------------------------------------------------------
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------------------------------------------------------------------------------
----
B. ----------------------------------------------------------------------------------
B ------------------------------------------------------------------------------
----
----------------------------------------------------------------------------------
C. ----------------------------------------------------------------------------------
B ------------------------------------------------------------------------------
----
----------------------------------------------------------------------------------

(Optional)

Name :
Designation :
Staff No. :
Department :
Mine :
Signature

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Feedback Form
(To be filled in by Stores - line managers / Supervisors)

Name of the Programme : Dumper Tyres

Venue :

Sl. Elements Improvement

No.
Very Little Some Good Excellent
little
1 What is the improvement in
cleanliness of storing place
2 What is the improvement in stacking
the tyre
3 What is the improvement in
inspecting before storing
4. What is the improvement in handling
of tyre in stores
5. What is the improvement in storing
tubeless tyres
6. What is the improvement in
avoidance of piling

Suggestions / Comments if any :

A. --------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
B. --------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
C. --------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
(Optional)
Name :
Designation :
Staff No. :
Department :
Mine :
Signature

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