A Framework For Preventing Underground Drill Rig Breakdowns: A Case Of Lubambe Copper Mine

Mining is the key sector to Zambia’s economic development. The sector is a major contributor to national export earnings and employment. Nevertheless, the importance of mining industry to the economy depends on sustained high levels of production output. As such, Lubambe Copper Mine (LCM) under Konkola North project was commissioned in 2010 with the view of producing 200,000 tonnes of Ore per month by 2014. However, this target could not be achieved due to the high rate of drill rig breakdown. Despite several attempts to address the problem of equipment breakdown, the situation still remained unresolved at Lubambe Copper Mine. 

This study therefore, sought to investigate the cause of the frequent drill rig breakdown. To explore and identify the causes of drill rig breakdowns at LCM, a multimethod approach was adopted and qualitative data provided deeper insights and explanations of the problem. A total of 134 copies of questionnaires were answered and 35 key informants were interviewed. Transcripts from qualitative questionnaires and interviews with key informants were uploaded and coded in NVivo and the ChiSquare from SPSS software package was used to determine association between variables and determining the p value, while the Z-Test was carried out to test the hypothesis, determine whether the identified factors influenced drill rig breakdowns at LCM and it was also used to validate the Chi-Square results.

The result of the study showed that human factors, environmental factors, maintenance factors and Supply Chain related factors were the cause of drill rig breakdowns at LCM. However, human related factors were identified as the major cause of drill rig break downs at LCM. The identified human related factors were low motivation and fatigue for drill rig operators and maintenance staff and inadequate training and development for drill rig operators. 

In Conclusion, a framework was proposed that could aid Executive Management to identify potential causes of drill rig breakdowns. The study further recommended that management at LCM should establish measures to improve and monitor the motivation of employees through appropriate compensation, reward systems and job design. Additionally, a maintenance culture based on precision was recommended. KEY WORDS: Productivity, Break down, Reliability, Maintenance, Availability