Reduction of production delay cost in underground coal mines: An FMEA-based method study approach

Coal is the backbone of the Indian economy, essential for electricity, steel, cement, and other vital items. Although India aims to be carbon emission-free by 2070, it must rely on coal for a few more decades. In the fiscal year 2021-22, India produced 96 percent of its coal from open-cast (OC) mines, whereas 70 percent of India's total coal reserve is in deep undergrounds. Despite underground (UG) coal mining being eco-friendly and yielding richer coal, its production cost is nearly four times higher than OC mining. Therefore, further research on UG mines is necessary to address these challenges. This study analyzed an underground coal mine production system in India and identified production delays as a major cost driver. Causes of delays were categorized by their association with machine, material, and man. An innovative technique, the Machine Criticality Score (MCS), has been developed to quantify production delay costs and guide management in mitigating them. Additional methods like failure mode and effects analysis (FMEA), standard operating procedure (SOP), inventory management tools, and method study were also used in this study to reduce production delay costs.