3.

Productivity Factors
EARTHMOVING 120404
PEMINDAHAN TANAH MEKANIS
Productivity Variable

 Factors that affect the productivity:

1. DIGGING RESISTANCE
• Caused by:
 Friction between digger with the material
 Material roughness : resisting the scooping process of the digger to the soil
 Particle and grain size
 Adhesion between digger and soil
 Cohesion inter-soil particle
 Material density
digging resistance
digging resistance
digging resistance
digging resistance
Rolling Resistance
Rolling resistance is the resistance of a level surface to constant-velocity
motion across. Rolling resistance results from friction of the driving
mechanism, tire flexing, and the force required to shear through or ride over
the supporting surface.

 Rolling resinstance depends on :

 Road condition (smoothness and hardness)
 Part of the unit which interact to the road surface
Rubber tire: size, air pressure, quality, tire surface
 Crawler track : will affect to the road form
 Rubber tire

Crawler type
Road type High Pressure Low Pressure Avg

lb/ton lb/ton lb/ton lb/ton

smooth concrete 55 35 45 40

Good aspalt 60-70 40-65 50-60 45-60

Hard earth, smooth, well maintained 60-80 40-70 50-70 45-70

Dirt road, average construction road, little maintenance 70-100 90-100 80-100 85-100

Dirt road, soft, rutted, poorly maintained 80-110 100-140 70-100 85-120

Earth, muddy, rutted, no maintenance 140-180 180-220 150-220 165-210

Loose sand and gravel 160-200 260-290 220-260 240-275

Earth, very muddy and soft 200-240 300-400 280-340 290-370

(Source: Peurifoy, et. al., 2006)

 Type of Road RR for Rubber tire

(lb/ton)

Hard, smooth surface, well maintained 40

Firm but flexible surface, well maintained 65

Dirt road, average contruction road, little maintenance 100

Dirt road, soft or rutted 150

Deep, muddy surface or loose sand 250-400

RR in Percentage
RR (lbs)
Road Type
Rubber Tire Crawler track
Concrete rough and dry 2% -
Compacted dirt and gravel, well
2% -
maintained, no tire penetration
Dry dirt, fairly compacted,
3% -
alight tire penetration
Firm, rutted dirt,
5% 2%
tire penetration appprox. 2"
Soft dirt fills,
8% 4%
tire penetration approx. 4"
Loose sand and gravel 10% 5%
Deeply rutted dirt, spongly
base, 16% 7%
tire penetration approx. 8"
 Grade Resistance
• The force-opposing movement of a machine up a frictionless slope
• It acts against the total weight of the machine, whether track by type or
wheel type.
• If a machine moves down a sloping road, the power required to keep it
moving is reduced in proportion to be the slope of the road. This is known as C
grade assistance.
D
EF/DE=BC/AC ----> P/W = BC/AC
P
P=W. BC/AC dimana AC = AB/cos θ 10 m
w
Asumsi w = 1 ton= 2000 lbs. Tan θ = 10/100 F
----> θ = arc tan (10/100) maka θ = 60
Cos θ  0.99, E B
A θ

100 m
sehingga P = 2000 lbs x (10 m /(100/cos θ))
= 200 lbs
Gradient GR Gradient GR Gradient GR

% lb/ton % lb/ton % lb/ton

1 20,0 9 179,2 20 392,3
2 40,0 10 199,0 25 485,2
3 60,0 11 218,0 30 574,7
4 80,0 12 238,4 35 660,6
5 100,0 13 257,8 40 742,8
6 119,0 14 277,4 45 820,8
7 139,0 15 296,6 50 894,4
8 159,0
Traction Coefficient
 Represents the percentage of the total engine power that can be converted
into forward motion by means of the friction between tire or track
 Coefficient of traction or friction refers to the maximum frictional force that
can be produced between surfaces without slipping
 Traction Coefficient depends on :
1. Tire condition and Tire Groove or Track Shape
2. Road condition or material (wet/dry, hard/soft, undulating/even)
3. The weight of unit which bore by the power train
Road type Rubber tire crawler track
dry, rough concrete 0,8-1,0 0,45
dry, clay loam 0,5-0,7 0,90
wet, clay loam 0,4-0,5 0,70
wet sand and gravel 0,3-0,4 0,35
loose, dry sand 0,2-0,3 0,30
Rimpull
 term that is used to designate the tractive between the tires of a machine’s driving
wheels and the surface on which they travel.

HP x 375 x machine efficiency

RP(i) = ------------------------------
Velocity (i) (mph)
Acceleration

 Time that is needed by the unit to accelerate by using the excess of rimpull
amount to drive forward in a certain circumstances
 Acceleration is affected by:
1. Unit weight
2. Rimpull excess

 How to determine acceleration:

1. a = (F x g)/w
2. Graphic (performance chart)
3. Empirical : every 20lb/ton of rimpull excess at certain gear will give 1 mins
time to achieve maximum velocity which gear shifting is needed
4. V avg = V maksimum x velocity factor
Operator (worker) Efficiency

 Operator efficiency is affected by:

a. Climate or weather
b. Unit or machine condition
c. Working environment and culture Rarely worker is doing the job at full 60 mins within
d. Personality 1 hour. The working time ratio to the available time
e. Others: is called by working efficiency. For example within 1
 Replacement hour, only 50 mins that being used for effective
 Lubricant work, so the efficiency will be = 83 %.
 cleansing
 removal To improve the efficiency, some efforts need to be
 Unfit co-worker done, such us incentives, supervising, reward and
 Waiting for progress punishment
 Road maintenance
Operator (worker) Efficiency
Operator Efficiency is also influenced by mechanical condition of the equipment

1. Availability Index or Mechanical Availability (AI)

illustrates for how much time the unit was available for production and not down for one of the
following reasons
AI = W/(W+R) X 100%

2. Physical availability (PA)

represents the percentage of time that equipment is able to operate but may (production time) or may not
(standby time, delay time) be "operating" due to reasons other than mechanical limitations
PA = (W+S)/(W+R+S) X 100%

3. Use of availability
Showing the percentage of time that being used by an equipment to operate when it is
available to work
UA = W/(W+S) X 100%

4. Effective utilization
Showing the percentage of time that being used by an equipment to operate on productive work
EU = W/(W+R+S) X 100%
Terminology

 Work (W) = waktu yang dibebankan kepada seorang operator suatu

alat yang dalam kondisi dapat dioperasikan, artinya tidak rusak.
Waktu ini meliputi pula tiap hambatan yanga ada, termasuk dalam
hambatan tersebut adalah waktu- waktu untuk pulang pergi ke
permuka kerja, pindah tempat, pelumasan, dan pengisian bahan
bakar, hambatan karena cuaca, dll.
 Repair (R) = waktu untuk perbaikan dan waktu yang hilang karena
menunggu saat perbaikan termasuk juga waktu untuk penyediaan
suku cadang serta waktu untuk perawatan preventif
 Standby (S) = standby hours atau jumlah jam suatu alat tidak
dapat dipergunakan padahal alat tersebut tidak rusak dan dalam
keadaan siap beroperasi
 W+R+S = schedule hours
Tugas
 Sebuah Proyek Galian memiliki volume sebesar 242.000 m3 yang bermaterial
lempung kering (dry clay), proyek ini menggunakan alat berupa
 2 unit Excavator Komatsu PC 450-7 dengan cycle time 27 detik,
 7 unit Truk Komatsu HD 325-6,
 dan di bantu oleh 2 unit Dozer Komatsu D85A-21.
 Hasil galian akan di timbun ke area yang berjarak 1 km dari daerah galian
dengan jalan menurun -5%. Hitunglah berapa lama proyek akan selesai jika
diasumsikan jam kerja satu hari adalah 10 jam dan Mechanical Availability
adalah 85%.

 Untuk spesifikasi alat dan grafik performance silakan lihat di komatsu

handbook
Project Profile
 Material dry clay (density 1.6 ton/m3)
 Insitu/Bank volume sebesar 242.000 m3
 Loose volume =346.060 m3 (LV)
 Excavator machine : 2 unit Excavator Komatsu PC 450-7
 Hauling unit : 7 unit Truk Komatsu HD 325-6,
 Hauling Road Profile
 Distance 1 km
 Grade 5%
 Mechanical Availibility 85%
 Working hours : 10 hours/day
 Assumption Working Efficiency : 83%
 Excavator Productivity
 Bucket capacity 1.9 – 2.1 m3 (A)
 Bucket fill factor 1.2 (B)
 Working hours 10 hours/day = 36.000 secs
 Cycle time 27 secs
 How Many cycle per day =
36000secs/27 secs = 1333 cycle (C)

 Mechanical Availibility 85% (D)

 Assumption Working Efficiency : 83% (E)
 Swelling factor 1.43

Prod Daily= A x B X C X D x E = 2,257 m3/day

2 excavator = 4514 m3/day (EX)

Day requirement = LV/EX = 76.6 day

 Truck Productivity
 Truk Komatsu HD 325-6
 Capacity 22.8 m3 (36.5 ton)
 Weight load = 27.2 ton + 36.5 ton = 63.7 ton
 Truck Cycle time
 Loading time
 N = (22.8 m3/(2 m3 x 1.2) ) = 9.5
Loading time = 9 x 27 secs= 243 detik (i)
 Hauling time (loaded) avg speed 38.5 km/hr
 Dist 1 km = 94 secs travel time (ii)
 Dumping time 1.15 min = 69 secs (iii)
 Returning time avg speed 50.35 km/hr
 Dist 1 km = 72 secs travel time (iv)
 Manuever time = 20 secs (v)
Truck Productivity
 Total cycle time = 243 s + 94 s + 64 s + 72 s + 20 s = 493 secs
 How Many cycle per day =
36000secs/493 secs = 73 cycle

 Daily Production = Truck Capacity x cycle per day x D x E

= 22.8 x 73 x 0.85 x 0.83 = 1174 m3/day per truck
 7 truck = 1174 m3/day x 7 = 8219 m3/day

 DAY requirement = 346.060 m3 : 8219 m3/day = 42 Days