Title of Invention

PERFORMANCE MONITORING SYSTEM AND METHOD.

Abstract A method for monitoring performance of at least one machine operator, said method comprising the steps of measuring at least one machine parameter during operation of the machine by the operator, said at least one machine parameter related to the operation of the machine by the at least one machine operator, generating at least one performance indicator distribution from measurements of the at least one machine parameter, said at least one performance indicator distribution comprising a range of values for a performance indicator derived from the at least one machine parameter andcalculating at least one performance indicator for the at least one machine operator from the at least one performance indicator distribution.
Full Text FIELD OF INVENTION
The invention relates to a performance monitoring system and method. In
particular, although not exclusively, the invention relates to a system and
method for monitoring the performance of equipment operators, particularly
operators of draglines and shovels employed in mining and excavation
applications or the like.
BACKGROUND OF THE INVENTION
In many fields of manufacturing and industry, it is desirable or necessary to
monitor the performance of equipment operators in addition to the equipment
itself. This may be for managerial purposes to ensure that operators are complying
with a minimum required standard of performance and to help identify where
improvements in performance may be achieved. Monitoring performance may also
be desired by an operator to provide the operator with an indication of their own
performance in comparison with other operators and to demonstrate their level of
competence to management.
One field in which performance monitoring is required is the operation of draglines
and shovels and the like as used in large-scale mining and excavation applications.
For commercial purposes, it is important that an operator is operating a piece of
machinery to the best of the operator's and the machine's capabilities.
There are however many factors that need to be measured and considered to
enable fair and useful comparisons to be made between different operators,
between different machines, between present and previous performances and
between different operating conditions.
OBJECT OF THE INVENTION
It is therefore an object of the invention to provide a method for monitoring
performance of atleast one machine operator which eliminates the disadvantages
of prior art.
Another object of the invention is to provide a method for monitoring performance
of atleast one machine operator, which makes possible that performance-
monitoring information is promptly available to inform management and operators
alike of current performance.
SUMMARY OF THE INVENTION
According to one aspect, although it need not be the only or indeed the broadest
aspect, the invention resides in a method for monitoring performance of at least
one machine operator, the method comprising the steps of:
measuring at least one machine parameter during operation of the machine by the
operator;
generating at least one performance indicator distribution from measurements of
the at least one machine parameter; and,
calculating at least one performance indicator from the at least one performance
indicator distribution.
The method may comprise the step of providing feedback to the operator by
displaying the at least one performance indicator in substantially real-time to the
operator. Alternatively, the at least one performance indicator may be displayed to
the operator once the machine has completed an operation cycle.
Suitably, the at least one machine parameter may be a dependent machine
parameter. Alternatively, the at least one machine parameter may be the sole
parameter represented by a particular performance indicator.
The method may comprise the step of segmenting at least one of the dependent
machine parameters into segments, the range of each segment constituting a
segmentation resolution.
Suitably, the step of segmenting at least one of the dependent machine parameters
comprises specifying a magnitude of the range for each segment of each
dependent machine parameter requiring segmentation.
Suitably, at least one dependent machine parameter may not require
segmentation.
Suitably, the step of generating the at least one performance indicator distribution
may comprise using a mixture of one or more distributions to model the
performance indicator distribution. The number of mixtures may be set
dynamically.
Suitably, the at least one performance indicator distribution may be generated
using an algorithm. The algorithm may be an LBG algorithm. Alternatively, the at
least one performance indicator distribution may be generated using a linear
ranking model (LRM).
Suitably, two or more performance indicators may be combined to yield an overall
performance rating of the machine operator. One or more of the performance
indicators may be positively or negatively weighted with respect to the other
performance indicator(s).
According to another aspect, the invention resides in a system for monitoring
performance of a machine operator, the system comprising:
at least one measuring device for measuring at least one machine parameter
during operation of the machine by the operator;
a server for generating at least one performance indicator distribution from
measurements of the at least one machine parameter; and,
a performance indicator calculation module for calculating at least one performance
indicator from the at least one performance indicator distribution.
Preferably, the server is remote from the machine.
Suitably, the server comprises storage means, communication means and a
performance indicator distribution calculation module.
Suitably, the performance indicator calculation module is onboard the machine.
Preferably, the performance indicator calculation module is coupled to
communication means for transmitting and receiving data to and from the
server.
Preferably, the system further comprises at least one display device for
displaying the at least one performance indicator in substantially real-time to the
operator. Alternatively, the at least one performance indicator may be displayed to
the operator once the machine has completed an operation cycle. The at least one
display device may be situated in, on or about the machine and/or remote from
the machine.
Suitably, the communication means comprises a transmitter and a receiver.
Further aspects of the invention will become apparent from the following
description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
To assist in understanding the invention and to enable a person skilled in the
relevant art to put the invention into practical effect preferred embodiments will
be described by way of example only and with reference to the accompanying
drawings, wherein:
FIG 1 shows a distribution of data representing a production key performance
indicator ( KPI);
FIG 2 is a schematic plan view of a machine showing segmentation resolution for
the swing angle parameter;
FIG 3 shows a distribution of Fill Production KPI data;
FIG 4 shows dragline data for the parameters start fill reach versus start fill
height;
FIG 5 shows calculation of a KPI for the right side of the distribution;
FIG 6 is a schematic representation of an Integrated Mining Systems (IMS)
system structure employed in the present invention;
FIG 7 shows a display of KPIs showing current real-time performance and a
comparison with performance for a previous cycle;
FIG 8 shows a display of KPIs showing current real-time performance;
FIG 9 shows an alternative display of KPIs showing both current real-time
performance and performance for a previous cycle;
FIG 10 shows an Operator Performance Trend Report; and
FIG 11 shows an Operator Ranking Report.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION
The present invention monitors one or more parameters or variables of a machine
to provide an accurate indication of how well an operator is performing, for
example, in comparison with other operators for the same machine and/or in
comparison with previous performances of the same operator.
Although the present invention will be described in the context of monitoring the
performance of machines found on a mining site, it will be appreciated that the
present invention is applicable to a wide variety of machines found in various
situations and performance monitoring is required.
A machine parameter may itself be referred to as a key performance indicator
(KPI). Alternatively, a KPI may be dependent on one or more machine parameters.
The KPIs may be represented and displayed as a percentage or a score, such as
points scored out of 10, that describes how well the operator is performing for a
given parameter and/or KPI. A high percentage value, such as >90% for
example, shows that the operator is performing extremely well. A mid-range
value for a KPI, such as 50% for example, shows that the operator's
performance is about average and less than this example percentage
demonstrates that their performance is below average for that KPI.
Each KPI parameter is related to the performance of an operator for one or more
given machine parameters such as fill time, cycle time, dig rate, and/or other
parameter(s). KPIs are a measure of how the operator is performing for the
particular parameter(s) related to that KPI compared to the other operators. The
performance of, or rating for, a particular operator is calculated using, in part,
previous data recorded for the machine and provides an indication of whether or
not the operator is improving. The process for measuring the parameters and
achieving the KPIs is described in detail hereinafter.
The parameter data is acquired using conventional measuring equipment such as
sensors, timing means and the like and the particular equipment required to
acquire the data would be familiar to a person of ordinary skill in the relevant
art.
Different comparisons between the data are also possible. The current operator
of a machine can be compared to all the other operators of the same machine or
to the operator's previous performance(s). This shows how well they perform
against others and shows them whether they are improving respectively.
One important consideration of the present invention is filtering the data from all
the machines that may be present in, for example, a mine site or other situation
to enable fair and meaningful comparisons to be made. Various factors that may
affect KPI parameters are as follows:
Machine: Each machine possesses different operating characteristics and
therefore the data from one machine will not reflect the performance of
operating another machine.
Dig Mode: Different dig modes are possible with a single machine and these may
differ between different machines, which is significant. In the present invention
operators can enter a particular dig mode corresponding to the mode of
operation of the machine. The selected dig mode must be correct otherwise the
KPIs may he mis-represented and provide misleading results.
Operator: Operators can compare their performance against their own
previous performances to verify whether they are improving. Operators can also
compare their performances against those of other operators.
Location: Different locations in the mine will have different digging conditions
even though the digging mode may be the same. This may be represented by
the specific gravity (s.g.) or by an index that describes the current digging
difficulty, known as the dig index.
Bucket: Some KPIs will be affected by the type of bucket being used on the
dragline. For example, different size buckets, which are usually pre-selected on
the basis of the application, may produce different dig rates. For comparison
purposes, an operator should not be disadvantaged when using a smaller bucket.
Bucket Rigging: If this factor changes, but the bucket does not, the KPI
results may be affected.
Weather: The weather can change the digging conditions and therefore
affect the performance attained by the operator.
Some of the above parameters are readily filtered from the data, such as
machine, dig mode, operator, bucket and possibly location. The more the data is
divided however, the more data needs to be processed, stored and transmitted
from the server 8 to the onboard computer module 4 (shown in FIG 6), to
implement the KPIs. To reduce this volume of data, the location parameter
could optionally be omitted, since location data is generally reflected in the
bucket type being used. Weather and bucket rigging are more difficult to filter.
Therefore, the parameter filters of machine, dig mode and bucket remain. These
parameter filters may be combined with the operator parameter filter.
If the data of all operators are to be compared, the operator filter is omitted.
When filtering by operator, the number of operators multiplies the amount of
data for the mine comparison. For example, if there are 1000 bytes of KPI data
to download to the module for the mine data and there are 100 operators, then
this equates to a total of 101,000 bytes of KPI data to download, which
represents 100 data sets for 100 operators plus one data set for the all operator
comparison.
This large data problem is one of the problems addressed by the present
invention, which enables the present invention to provide substantially real-time
monitoring of operators' performance.
The large data problem can be solved in a number of ways. One option is to
only download KPI data for the operators that exist in the recorded data in the
database. Alternatively, only KPI data for operators that have ever logged onto
a particular machine, which is stored in an operator profile, may be downloaded.
For any new operator who logs on, the data is requested and downloaded. If the
data does not exist in the database, then the display can show that there is no
KPI data for that operator. Another alternative is to just download the KPI data
for the operator that just logged on.
Even with the data filtering described above, a single value such as fill time,
cannot be compared to other fill times unless one or more dependencies are
introduced. Some KPIs, such as the Machine Reliability KPI, do not require a
dependent parameter, but many do, such as the Swing Production KPI. A
dependent parameter adds another level of filtering to the data that is specific to
the parameter being rated.
A simple example is the Swing Production KPI. The time taken to swing a
dragline, for example, is directly related to the angle through which the dragline
swings (Swing Angle) and the vertical distance the bucket travels from the end of
a fill to the top of a dump of the bucket contents. These dependencies are
included in the KPI calculation by segmenting each of the dependent parameters
into ranges. The range of the segment is called the segmentation resolution. The
swing angle in this example could be divided into 10-degree increments over, for
example, 360 degrees. If the vertical travel distance is ignored in this example,
this would provide 36 data segments.
To calculate the KPI, the data recorded from that machine is sorted, for example,
by dig mede, for each of the segments. For the data associated with each
segment, a KPI distribution is calculated. Therefore, for the Swing Production KPI
example, the swing times for each swing angle segment are extracted and a
distribution of times is calculated for each segment. Thus, 36 distributions would
be calculated in total. The actual swing times and swing angles are measured
onboard the machine using conventional timing and angle measuring
instruments that are familiar to those skilled in the relevant art. The distribution
associated with the swing angle segment being measured is then selected to
calculate the KPI.
Introducing more dependent variables creates the problem of producing more
data segments, which in turn means more distributions and more data. In the
example above, if the vertical distance was included and divided into, for
example, 10 metre segments from 0 to +70 metres (7 segments), there would
be 252 (36 x 7) distributions to calculate and download to the machine just for
the Swing Production KPI.
The volume of data can be reduced by carefully designing the segmentation of
the dependent parameters. One way is to include extremities in the
segmentation, which allows only segmentation of the areas that are common. In
the above example, the swing angle could be re-segmented such that one
segment contains swing angles less than, for example, 30 degrees and another
segment contains swing angles greater than, for example, 200 degrees whilst
maintaining the 10-degree segments between 30 degrees and 200 degrees. This
re-segmentation results in 19 segments for the swing angle parameter compared
with 36 in the previous example.
The vertical height dependency could be reduced to 2 segments by identifying
the height at which the swing velocity is reduced (i.e., for hoist dependent
swings). Less than this height is one segment and above this height is another.
This reduces the total number of segments to 38 (2x19) segments.
As described in the foregoing, a distribution exists for each segment of the KPI
that is dependent on some other parameter. Finding a distribution that describes
the KPI data is not trivial. Even though the sampled data looks Gaussian in
nature, the graphs are skewed and comprise some data at the extremities.
FIG 1 shows some data taken for the KPI representing production. All the other
KPIs show a similar distribution. FIG 1 shows a positive skew in the data and
some data to the right of the graph. A simple Gaussian would model most of this
data quite adequately. However, it cannot be judged how the data will skew or
how the distribution will change once the KPI information is available to the
machine operator. It is likely that the distribution will become more positively
skewed and less Gaussian like.
One solution to this problem is to model the data with a multi-modal or multi-
variant Gaussian mixture in which a mixture of different Gaussian distributions
are used to model each KPI distribution. This has the advantage that the number
of mixtures can be changed depending on the data. If the data is very Gaussian-
like, then a single mixture comprising a simple Gaussian distribution may be
used. If the data is very obscure, then a plurality of mixtures can be used to
describe the distribution.
The number of mixtures depends on the data that is being modeled and the
number of mixtures may be set dynamically. With sufficient data, an algorithm
could be employed to determine the maximum number of mixtures required to
represent the KPI distribution. If there is only a small amount of data, for
example less than a selectable threshold of 10 samples, then modeling may be
carried out using a single mixture. If the algorithm does not converge with the
maximum number of mixtures, the highest number of mixtures that cause the
algorithm to converge can be used.
One algorithm that could be used to generate the KPI distributions from the data
is a Linde-Buzo-Gray (LBG) algorithm, which is known to persons skilled in the
relevant art. The LBG algorithm is an iterative algorithm that splits data into a
number of clusters. The algorithm is designed for vectors, but in the present
invention, single dimension vectors (single values) are used, thus simplifying the
algorithm.
The detail of the LBG algorithm will now be described. xm = {x1,x2,...,xM} is the
training data set consisting of M data samples. Cn = {c1 ,c2,...,cN} are the
centroids calculated for N clusters, s is the iteration conversion coefficient, which
is usually fixed to a small value greater than zero, such as 0.01.
The steps for generating the KPI distributions are as follows:
1. N=l and given x, calculate the initial centroid c, by calculating the
mean:
2. Calculate the initial distortion of the data for the initial centroid:
3. Set iteration index I=0.
4. Find the cluster p with the maximum distortion.
5. Increment the number of clusters: N = N +1
6. Split cluster P into 2:
7. For all 1 where n*is the index of the centroid:

and the total number of values assigned to each centroid Tn.
8. Calculate the new centroids:

9. i= i+ 1.
10. Calculate the average of the minimum distortion between the data sample
and its closest centroid:
11. If ( , then go back to step 7.
12. Save the temporary calculation centroids in a secure location.
13. If the number of desired clusters has not been reached, then go back to
Step 4.
The algorithm starts by treating the whole of the data as one cluster. It then
divides the cluster into two and iteratively assigns data to each of the clusters
until the centroids of the clusters do not move appreciably. Once the iterations
converge, the cluster with the greatest spread (accumulative distance between
data and centroid) is split and the iterative calculations are repeated. The
algorithm continues until the required number of clusters has been reached. The
result is data divided into clusters with centroids. The data for each cluster is
then used to calculate a mean and standard deviation for that cluster, i.e. a
distribution. The weight of each cluster is calculated as the number of data
samples in the cluster compared to the total number of data samples. This
weight is known as the mixture coefficient.
In order to calculate the KPI from the distributions, the following formula for a
multi-variant Gaussian distribution is employed:

where p(x) is the probability, Cn is the mixture coefficient and N(x,µ,s) is
represented by the following formula:

which is a standard Gaussian distribution with mean µ. and standard deviation a.
Another solution to the problem of modeling the data to generate the KPI
distributions is to use a Linear Ranking Model (LRM). Instead of modeling the
distribution of each of the segments for each KPI, the LRM models the
distribution in such a way that only the minimum and maximum boundaries need
to be calculated. All values between these limits are then ranked according to
their position between the minimum and maximum. This method has the
advantage that it is distribution independent.
One problem with the LRM is that is does not handle outlying data very well. For
example, with reference to the Fill Production data shown in FIG 3, there is an
amount of data to the right of the graph (caused possibly by abnormal cycles).
The minimum and maximum values respectively on the abscissa are 0.33 and 34
(units =mass per unit time interval) for this example. This means that the
majority of the operators would obtain a low score and very few would obtain a
high one since the majority of Fill Production values would occur in the lower half
of the ranqe.
A solution to this problem is to filter off the erroneous data. This can be achieved
by removing data that is more than 3 standard deviations from the mean (keep
99% of the data for true Gaussian curve). The new minimum and maximum are
-0.70 and 17.6. The negative minimum would be set to zero and any values
greater than the maximum are then deemed 100%.
Another consideration is that most of the scores obtained by the operator will be
around the average because we are modeling a Gaussian-like distribution using a
linear model. That is, as most of the data is centred on the mean, the majority of
the scores wili be around the mean. There is also the consideration that the
scores are represented as a percentage, which no longer has a physical meaning.
Instead, the operator will receive a score out of 10.
The solution for the threshold problem is to calculate the thresholds in the office.
The mean sets the lower threshold so that if the operator obtains a score below
this then the operator is below average. For the upper threshold, the threshold
for the top 10% of operators can be found. The data used to calculate these
thresholds is all the data for each KPI without segmentation. The threshold is
then the average score of the thresholds over the KPIs. This means that we have
a set threshold for all KPIs and one that does not vary from cycle to cycle.
The score for the KPI using the Linear Ranking Model is the ratio between the
value and the difference of the minimum and maximum. This value is then
multiplied by 10 to produce the KPI score. The following equation shows the
calculations required:

TABLE 1 below shows the advantages and disadvantages of the LRM and LBG
methods for generating the distributions.
The parameters represented by KPIs and their dependent parameters are:
Swing Production = Load Weight / Swing Time
Swing Angle
Hoist Dependent Swings
Fill Production = Load Weight / (Fill + Spot Times)
Start Fill Reach
Start Fill Height
Return Time
Swing Angle
Production Performance
This is a weighted sum of the 3 KPIs above.
Machine Reliability
Hence, there are 5 KPIs and 4 different dependent parameters. The Hoist
Dependent Swings parameter does not require segmentation at all, as it is a
Boolean. That leaves only 3 dependent parameters for which segmentation
needs to be described.
However, it will be appreciated that the present invention is not limited to
theparticular KPIs specified above, the number of KPIs, nor the different
dependent parameters. It is envisaged that other parameters and KPIs and
combinations thereof may be utilized in future, depending particularly on, for
example, the particular application.
In accordance with the present invention, a segmentation resolution is set for
each dependent parameter in the database structure, except for the Hoist
Dependent Swings parameter as previously explained. The segmentation
resolution specifies the relevant variable(s), such as distance, angle, and the like,
for a single segment. For example, if the segmentation resolution for Swing
Angle were 15 degrees, then data would be extracted for each 15-degree
segment, as indicated in FIG 2. Only four segments are shown in FIG 2. A
weighted sum of the first 3 KPIs may then be calculated to obtain an overall
production performance rating.
Segmentation is performed from a single known point (such as the origin in the
case of the Start Fill Reach and Height). The data is then segmented from this
point based on the segmentation resolution as explained above. Segments
continue until the maximum or minimum limit is reached.
For example, FIG 4 shows fill time data for different Fill Reaches and Heights. In
the order of darkest to lightest shading of the data points, the points represent
fill times, t, of t 30s. The segments
would be divided such that they start at 0 cm and extend out to the 10,000 cm
extremity for Fill Reach. For Fill Height, the segments would extend up to the
1,000 cm extremity and down as far as the -3,500 cm extremity.
The reason to perform the segmentation in this way is so that the distributions
represent a fixed set of conditions even after a period of time. This way, data
that was logged, for example, a month ago can be fairly compared with current
distributions.
Another setting for the KPIs related to the segmentation is the calculation of a
probability from the distribution. If a better performance is achieved by a lower
KPI value, the right side of the distribution needs to be calculated to obtain the
KPI, as shown in FIG 5. The Return Time KPI is an example of such a KPI. The
left side of the distribution is calculated when a KPI value is required to be higher
to achieve better performance. The Swing Production and Fill Production KPIs
are examples of such a KPI.
FIG 6 shows the structure of an Integrated Mining Systems (IMS) system 2. A
Series 3 Computer Module 4 and associated Display Module 6 are located in each
machine being monitored on site. An IMS server 8 may also be located on site,
for example in the site office, or it may be located at some other remote location
providing communication within the Telemetry constraints is possible. The IMS
server 8 comprises storage means in the form of a database 10, calculation
means in the form of KPI distribution calculation module 12, communication
means in the form of telemetry module 14 and application module 16 for the
generation and editing of KPI reports.
The Database 10 also needs to store the KPI Distributions that are generated
from the cycle data. A number of distributions are stored in the Database 10.
The first set of Distributions model the data for that machine for all operators. A
set of Distributions will then exist for each operator. The feedback onboard can
then be compared to all operators for that machine or to the currently logged on
operator.
An overview of the Database Structure is described below.
TABLE 2 - KPI Configuration Information

The KPI Configuration information describes the global settings used in the
system as shown in TABLE 2. The KPI Parameter ID identifies the parameter
used in the calculation of the distributions and the comparisons. The text
description is used to display the KPI name on the Reports/Forms. The maximum
number or mixtures is set here when using the LBG method. The maximum is
likely to be 4, but this will probably vary depending on the KPI. The number of
mixtures that are actually used can be smaller than this number. The Left or
Right distribution value determines how to calculate the KPI onboard the
machine. As discussed above with reference to FIG 5, if it is a left distribution,
then it means that a higher KPI variable is required to obtain better performance,
e.g. Return Time. A right distribution means that a lower KPI is required to
obtain better performance, e.g. Swing Production. A moving average filter can be
optionally applied to the KPI result.
TABLE 3 Segment Information

The Segment Information contains all the combinations of machines, dig modes,
buckets, and operators in the mine for each KPI and associated segments as
shown in TABLE 3. The KPI Distribution Calculation routine inserts all the entries
into this table after it has determined the segmentation of the data. The
segment ID identifies the segment for the current KPI, machine, dig mode, and
the like.
TABLE 4 Segmentation Offset Information
The Segmentation Offset Information contains the offset values for dependent
parameters associated with a KPI as shown in TABLE 4. These need to be
configured for each machine for which KPI distribution calculations will be
performed.
TABLE 5 Dependency Information
The Dependency Information contains the high and low limits for each
dependent parameter within each segment and is calculated by the KPI
Distribution Calculation routine.
TABLE 6 Distribution Information for the LBG method
The Distribution Information contains the distribution models for each of the
segments. The information stored here depends on the distribution calculation
method that is employed.
For the LBG method, TABLE 6 shows the information that is used. For each
segment the mixture weight, mean and standard deviation are stored for each
mixture within the segment.
TABLE 7 Distribution Information for the LRM method.
For the LRM method, TABLE 7 shows the information that is used. For each
segment the maximum and minimum distribution values are stored.
TABLE 8 Parameter Link Information
The Parameter Link information shown in TABLE 8 is used to allow parameters to
be associated with a KPI. Values for associated parameters that are not
dependent will be added to values for the KPI. Other parameters are dependent
parameters.
TABLE 9 Parameter Information
The Parameter Information shown in TABLE 9 is used to identify the KPI
Parameter ID with which the parameter is associated. This is used to identify
which KPI parameter and dependent parameters are used in the modeling.
The KPI Distribution Calculation routine is an NT service that is scheduled to run
on a periodic basis.
The program collects the data, segments it and calculates the distributions for
each segment and stores the results in the Database 10. While this program is
running, the system (mainly Telemetry module 14) knows not to acquire any of
the data from any of the KPI tables. This is because this program may take an
order of hours to calculate all the data. It may be necessary to set the priority of
this task to low in the system in case the processing time is significant.
The requirements for Telemetry are simple and would generally be familiar to a
person skilled in the art. The onboard computer module 4 shown in FIG 6 needs
to request the KPI parameters that are currently in the database, but only if they
have been changed. The onboard module 4 will request the data, for example,
every 8 hours. If the KPI Distribution Calculation routine is running then
Telemetry needs to instruct the onboard module 4 to defer the request until
later. It does this by setting a KPI timestamp in the reply packet to zero.
The timestamp when the data was last changed is recorded in a table in the
database. The onboard module 4 will send an initial KPI request packet as
described later herein. Telemetry replies with the basic KPI configuration data
and the timestamp of when the service last ran. If the service is running the
timestamp is set to zero. The timestamp is also sent with every packet during
the download so that if the service starts while downloading, the onboard
module 4 can detect that the timestamp has gone to zero and it can abort the
download.
The Telemetry Packet Structures will now be described.
The onboard module 4 sends a KPI Configuration Request packet to Telemetry
module 14 to request the KPI configuration. Telemetry module 14 replies with a
KPI Configuration packet, for which the contents are shown in Table 10. It places
the timestamp in which the KPI Distribution Calculation Routine last ran into this
packet. The onboard module then compares this timestamp with the one it has
to see if it needs to start downloading the KPI segments.
TABLE 10 - KPI Configuration Packet

A KPI Segment Request packet, as shown below in Table 11, requests the data
(distributions and the like) from Telemetry module 14. The reason for including
the Dig Mode ID, bucket ID and the operator ID in the packet is to enable
prioritization of the download of the KPI distributions if required.
The first packet contains a segmenMndex of 1 to request the first segment and
subsequent packets contain the next segment that the system wants. The
requests stop when all the segments for that machine have been downloaded.
TABLE 11 - KPI Segment Request packet

A KPI Segment packet shown in Table 12 below is the reply to the KPI segment
request packet. If there is no distribution for the segment, then the Distribution
information contains nothing.
TABLE 12 - KPI Segment packet

The Series 3 Computer Module 4 shown in FIG 6 needs to download the KPI
configuration and distribution information from the server 8, which is stored
onboard in Flash memory. Once this information is downloaded, performance
indicator calculation module 18 of onboard computer module 4 is responsible for
calculating the KPI scores after every cycle as previously described herein. If the
LBG algorithm method described above is being used, a Gaussian lookup table
may be used to calculate the Gaussian curve instead of using the Gaussian
distribution equation specified above.
In order for the Series 3 Computer Module 4 to calculate the operator's score, it
firstly selects the distribution by determining the segment that the current cycle
matches for the particular KPI. Once the distribution has been found, then the
KPI score can be calculated. If there exists no distribution to calculate a KPI,
then the KPI score will be 100% (or 10 if the LRM is being used).
The scores for all the KPIs are calculated for both the mine and current operator
comparison. Therefore, there are 2 scores that need to be calculated for every
KPL
The KPI can be displayed on display module 6 as a real-time parameter in the
parameter list on a STATS screen. It may also be displayed as a trend so that the
operator can see any performance improvements or deteriorations. The trend
may be configured by the operator to show the graph for the last hour or the
current shift or other suitable period. This is performed using the KPI trend
configuration that is displayed once the operator selects one of the trend graphs
from a menu displayed on the STATS screen.
A third option is to display a KPI indicator that is again selected in the trend
configuration. Three different designs for the indicator are shown in FIGS 7-9
The KPI indicator could appear white against a black background to enhance
visibility. FIG 7 shows the current real-time performance. The arrows above
each KPI indicate whether or not the score has improved from the last cycle.
The extent to which the KPI has improved or deteriorated may also be shown.
FIG 8 shows an alternative method of displaying the real-time KPI scores for
each of the KPI variables including an overall performance rating, which may be
the average of the KPI variables. FIG 9 shows an alternative way of displaying
the scores for the previous cycle so that the operator can judge any
improvements or deteriorations from cycle to cycle. This version could include
more than just the last cycle.
The IMS Application module 16 preferably supports editing of at least some of
the KPI Parameters. The following parameters need to be available to an
administrator for editing: KPI text description; the setting of the good and
average thresholds for the KPI indicator; frequency of running the KPI
Distribution Calculation routine (KPI Statistical Generator); number of days of
previous data to be used to create the models; display of the last time the KPI
data was updated and the like.
Reports, such as an Operator Performance Trend Report and an Operator
Ranking Report, as shown in FIG 10 and FIG 11 respectively, may also be
generated from the Report Manager in the IMS Application.
The Operator Performance Trend report shows the graphical trend of an
operator for each of the selected KPI variables. The options that should be made
to the person generating this report should include: Sort by machine, Sort by dig
mode, Sort by bucket, Set Time period, Number of operators to show (top,
specified number or all) and The KPIs to show.
The Operator Performance Trend report needs to calculate the KPI values over
the selected time period based on the distributions contained in the Database at
the time. Therefore, the KPI scores need to be calculated again. The reason for
this is that the scores that were shown to the operator onboard are no longer
valid because the distributions would have changed during that time and
therefore cannot be compared to each other. Because the Report Manager has
to do these calculations, the report may take a long time. Therefore, the time
period over which the trends are calculated will have to be limited.
The Operator Ranking report displays the ranking of operators for each of the
KPIs. That is, for a particular KPI or all KPIs, it displays the ranking of all the
operators. The time period needs to be selected and, as for the previous report,
this time period will have to be limited as the report may take a long time to run.
This report needs to calculate what the previous report calculated, but needs to
average the output scores.
The options that should be made to the person generating this report should
include: Sort by machine, Sort by dig mode, Set Time period, Number of
operators to show (top, specified number or all), The KPIs to show.
An Average Production KPI may be provided that may be calculated remotely
and downloaded to the Series 3 computer module 6 in the machine. This may be
displayed on the performance graphs to show the operator their current
performance relative to their average. This value can be downloaded along with
the operator ID lists.
Current practice used by all mines estimating operator performance on the basis
of Productivity appears to be wrong. Under different conditions and production
plans some of the operators could be disadvantaged against others. For
example, if an operator works in the same conditions, but with different swing
angles from another operator, productivity shown for the greater swing angle will
be less than for smaller swing angle, even though the first operator may in
reality be more efficient.
Taking into account that the number of effecting factors could include a number
of other parameters, the applicant has identified that in order to be able to
compare productivity ranks of the same operator under different conditions,
some integrated value that could be used for ranking purposes should be used.
In order to be able to calculate average rank for operators working under
different conditions, integrating performance ranks achieved under different
conditions by different operators should be considered on the one hand and
mine interests and production performance should be considered on another
hand.
The suggested method of the present invention in this regard will include these 2
parameters as variables and will allow calculation of average operator rank,
which could be used as a universal rank among the mine for different machines,
conditions and production plans.
The formula for calculation of average operator rank is presented below:
Av Op Rank = W1 * R1 + W2*R2+....+ Wi*Ri
where:
Wi - Weight coefficient for Parameter Subset i, which is calculated on the basis
of statistical information for the mine indicating the weight of i Parameter subset
for the mine applicable to operator I; and
Ri - Rank of the operator i achieved for this Parameter Subset i.
For example, let it be assumed that during a reporting period a mine used only
four different subsets of parameters. The weight of each subset could
respectively be the following: 25%, 20%, 40% andl5%. If operator #1 worked
only under subset #1 and # 2 and achieved 90% for subset # 1 and 94% for
subset #2, using the above formula the average rank for the operator may be
calculated:

For Operator # 2, subset #3 = 92% and subset # 4 = 90%. Hence:

These Productivity ranks do not include Production figures and only rank
operators for different subsets of parameters. In reality, if, for example, operator
#1 was doing cycles with swings of say 10 and 20 degrees and operator #2
swings of say 170 and 180 degrees, then the real production for operator #1
could be twice as much as for operator # 2, but in fact the rank of operator # 1
is higher and accordingly he is better.
It is also conceivable that the average performance of an operator over the last
week or month could be shown. The average performance could be calculated
remotely and the onboard module would download it to the machine for every
operator. It would be treated just as a list download where one radio packet
represents one graph. Only the minimum and maximum values need to be sent
and then each of the data points can be percentage scaled.
Accurately determining one or more of the KPIs in accordance with the present
invention addresses the difficulties of accurately measuring relevant parameters
and producing fair comparisons. The present invention can be used to improve
awareness of how well the operators are performing and provide an incentive to
improve performance. It also provides an indication to management about who
is performing well and which operators are not performing up to standard.
Throughout the specification the aim has been to describe the invention without
limiting the invention to any one embodiment or specific collection of features.
Persons skilled in the relevant art may realize variations from the specific
embodiments that will nonetheless fall within the scope of the invention.
WE CLAIM
1. A method for monitoring performance of at least one machine operator,
said method including the steps of:
measuring at least one machine parameter during operation of the
machine by the operator, said at least one machine parameter related to
the operation of the machine by the at least one machine operator;
segmenting at least one machine parameter that is a dependent machine
parameter into segments where at least one dependent machine
parameter exists, the range of each segment constituting a segmentation
resolution;
generating at least one performance indicator distribution from
measurements of the at least one machine parameter, said at least one
performance indicator distribution comprising a range of values for a
performance indicator derived from said at least one machine parameter;
calculating at least one performance indicator for the at least one machine
operator from the at least one performance indicator distribution;
displaying the calculated performance indicator; and monitoring the
performance of the at least one machine operator using the at least one
calculated performance indicator.
2. The method as claimed in claim 1, comprising the step of providing
feedback to the operator by displaying the at least one performance
indicator in substantially real-time to the operator.
3. The method as claimed in claim 1, comprising the step of providing
feedback to the operator by displaying the at least one performance
indicator to the operator once the machine has completed an operation
cycle.
4. The method as claimed in claim 1, wherein the at least one machine
parameter is a dependent machine parameter.
5. The method as claimed in claim 1, wherein the at least one machine
parameter Is the sole parameter represented by a particular performance
indicator.
6. The method as claimed in claim 1 wherein the step of segmenting at least
one of the dependent machine parameters includes specifying a
magnitude of the range for each segment of each dependent machine
parameter requiring segmentation.
7. The method as claimed in claim 4, wherein at least one dependent
machine parameter does not require segmentation.
8. The method as claimed in claim 1, wherein the step of generating the at
least one performance indicator distribution comprises using a mixture of
one or more distributions to model the performance indicator distribution.
9. The method as claimed in claim 8, wherein the number of mixtures is set
dynamically.
10.The method as claimed in claim 1, wherein the at least one performance
indicator distribution is generated using an algorithm.
11.The method as claimed in claim 10, wherein the algorithm is a Linde-
Buzo-Gray (LBG) algorithm.
12.The method as claimed in claim 1, wherein the at least one performance
indicator distribution is generated using a linear ranking model (LRM).
13.The method as claimed in claim 1, wherein two or more performance
indicators are combined to yield an overall performance rating of the
machine operator.
14.The method as claimed in claim 13, wherein one or more of the
performance indicators are positively or negatively weighted with respect
to the other performance indicator(s).
15. A system for monitoring performance of at least one machine operator,
said system comprising:
at least one measuring device (12) for measuring at least one machine
parameter during operation of the machine by the operator, said at least
one machine parameter related to the operation of the machine by the at
least one machine operator;
a server (8) for segmenting at least one machine parameter that is a
dependent machine parameter into segments where at least one
dependent machine parameter exists, the range of each segment
constituting a segmentation resolution and for generating at least one
performance indicator distribution from measurements of the at least one
machine parameter, said at least one performance indicator distribution
comprising a range of values for a performance indicator derived from
said at least one machine parameter;
a performance indicator calculation module (18) for calculating at least
one performance indicator for the at least one machine operator from the
at least one performance indicator distribution;
a storage unit (10) for storing the calculated performance indicator; and
a display device (6) for displaying the calculated performance indicator,
wherein the calculated performance indicator for the at least one machine
operator is used to monitor the performance of the at least one machine
operator.
16.The system as claimed in claim 15, wherein the server (8) is remote from
the machine.
17. The system as claimed in claim 15, wherein the server (8) comprises:
storage means (10);
communication means (14);
and a performance indicator distribution calculation module (18).
18.The system as claimed in claim 15, wherein the performance indicator
calculation module (18) is onboard the machine.
19. The system as claimed in claim 15, wherein the performance indicator
calculation module (18) is coupled to communication means (14) for
transmitting and receiving data to and from the server.
2O.The system as claimed in claim 15, wherein the at least one display device
(6) displays the at least one performance indicator in substantially real-
time to the operator.
21.The system as claimed in claim 15, wherein the at least one display device
(6) displays the at least one performance indicator to the operator once
the machine has completed an operation cycle.
22.The system as claimed in claim 15, wherein the at least one display device
(6) is onboard the machine.
23.The system as claimed in claim 15, wherein the at least one display device
(6) is remote from the machine
A method for monitoring performance of at least one machine operator, said
method comprising the steps of measuring at least one machine parameter
during operation of the machine by the operator, said at least one machine
parameter related to the operation of the machine by the at least one machine
operator, generating at least one performance indicator distribution from
measurements of the at least one machine parameter, said at least one
performance indicator distribution comprising a range of values for a
performance indicator derived from the at least one machine parameter
andcalculating at least one performance indicator for the at least one machine
operator from the at least one performance indicator distribution.

Documents:

1044-KOLNP-2004-CORRESPONDENCE 1.1.pdf

1044-KOLNP-2004-CORRESPONDENCE 1.3.pdf

1044-KOLNP-2004-CORRESPONDENCE-1.2.pdf

1044-KOLNP-2004-CORRESPONDENCE.pdf

1044-KOLNP-2004-FORM 27 1.1.pdf

1044-KOLNP-2004-FORM 27.pdf

1044-KOLNP-2004-FORM 3-1.1.pdf

1044-KOLNP-2004-FORM-27.pdf

1044-kolnp-2004-granted-abstract.pdf

1044-kolnp-2004-granted-claims.pdf

1044-kolnp-2004-granted-correspondence.pdf

1044-kolnp-2004-granted-description (complete).pdf

1044-kolnp-2004-granted-drawings.pdf

1044-kolnp-2004-granted-examination report.pdf

1044-kolnp-2004-granted-form 1.pdf

1044-kolnp-2004-granted-form 18.pdf

1044-kolnp-2004-granted-form 2.pdf

1044-kolnp-2004-granted-form 26.pdf

1044-kolnp-2004-granted-form 3.pdf

1044-kolnp-2004-granted-form 5.pdf

1044-kolnp-2004-granted-reply to examination report.pdf

1044-kolnp-2004-granted-specification.pdf

1044-KOLNP-2004-PETITION UNDER RULR 137.pdf


Patent Number 223037
Indian Patent Application Number 1044/KOLNP/2004
PG Journal Number 36/2008
Publication Date 05-Sep-2008
Grant Date 03-Sep-2008
Date of Filing 22-Jul-2004
Name of Patentee LEICA GEOSYSTEMS AG
Applicant Address HEINRICH-WILD-STRASSE, CH 9435 HEERBRUGG
Inventors:
# Inventor's Name Inventor's Address
1 LILLY BRENDON 977 STANLEY STREET BAST, BAST BRISBUNE, QLD 4169
PCT International Classification Number G06F 17/40, 17/60
PCT International Application Number PCT/AU03/00077
PCT International Filing date 2003-01-24
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 PS0173 2002-01-25 Australia