Trackless Mobile Mining Machinery Operation “Safety Risk Model Trackless Mobile Mining Machinery Operation for South African Open Pit/Cast Operations An Industry wide perspective

Open Cast/Pit MOSH

Purpose The model is a corner stone for the MOSH initiative’s process to identify Leading Practices with the potential to make the biggest contribution to industry wide Safety performance for trackless mobile mining machinery operation

Outcomes of the exposure Level One: Overall Model Equipment Short term outcomes Injury Disability Death Production loss Sec 54 Sec52 Body and organ vibration Hand and feet injuries All ranges of body injuries Nature of Exposure Operator Nature of the Hazard Exposures Outcomes of the exposure Information Exposed persons Environment Machine Operators Maintenance Technicians Workers/Pedestrians Long term outcomes Injury Disability Death Lower ROI Increased regulation Compensation Equipment operation

Level two: Sources of Equipment Hazards OEM Inadequate definition of use/poor understanding of use. Inadequate field testing of equipment/components Inadequate risk analysis for specific requirements OEM design process inadequate Inadequate user field feedback systems Lack of safety engineering competence Inadequate operability and maintainability analysis Poor/no Human factors engineering Inadequate design specifications Company Lack of user acceptance testing of new equipment designs Inadequate user requirements specifications Equipment Fatigue failure of safety related components Nip point on machines Inadequate Safety Systems Design Difficult/poor access for Persons working on Vehicle Machine fires Poor Ergonomics/HF of Machines Inadequate provision For Visibility Difficult/poor access for operators Poor Maintainability/maintenance access Poor reliability of Safety Systems Poor provision of Safety Systems by OEMs Level two: Sources of Equipment Hazards Level three: Causes of Equipment Hazards Equipment failure

Level two: Sources of Operator Hazards Poor fitness For work Operator complacency Inadequate training Inadequate competency assessment –no emergency simulation Dangerous Operating of machine Operator Fatigue Poor Literacy/ risk comprehension Poor Safety Culture Pre use inspection Man / Machine misfit Old drivers No test of risk Comprehension Inadequate driver training and experience Production pressure Poor risk comprehension Over confidence/familiarity Lack of emergency experience Poor eye sight Physically unfit Medication impact Poor Health High risk tolerance Cultural National Social Lack of understanding cause & effect Overly elaborate check list Checklist/Literacy level mismatch Checklist not risk based Complacency No review of checklists Poor selection criteria (Ergonomic review) Historic selection New model machines old operators Not using / wrong use of PPE Familiarity Poor safety culture Inappropriate PPE Ineffective PPE Double standards Poor understanding of importance of training Inexperience with training design Cost of effective training programmes Difficulty to measure training effectiveness Bridging safety devices Nuisance alarms Poor reliability Sabotage perceived production impact of importance Inexperience with design of competence assessment Challenges to measure Risk to simulate Cost to simulate Level three: Causes of Operator Hazards Machine Vibration Lack of sleep Shift patters Distance from work Repetitive work Poor discipline wrt medical Substance abuse Social conditions Poor physical condition Poor mental condition

Level two: Sources of Equipment Operation Hazards Inadequate understanding of fully functioning equipment and safety relationship Level three: Causes of Equipment Operation Hazards Inadequate understanding of leading practices in traffic management Traffic management not fundamental mine design focus Inadequate traffic management Poor equipment health standards Poor safety culture Inadequate understanding of full functioning equipment and safety relationship Capital cost constraints Non systemic approach to mine design changes Safety impact assessments not always done Temporary vs Permanent Production only considerations Inadequate mine design/layout/ mine capacity changes Lack of maintenance infrastructure Inadequate awareness of new and leading practices Poor continuous improvement process Capital constraints Reviews after incidents inadequate Equipment operation Safety controls too low on hierarchy of controls Operating procedures evolved over many years No physical verification of operating procedures Office based procedure review Composition of review teams Sub-standard and unpractical operating procedures Mismatch of operating procedures and mine design. Poor management of mine design changes New operating procedures not considered and/or not practically verified before issuing Copy and paste of procedures Poor roads-surface and gradient maintenance Roads-surface and gradient standards are inadequate Poor safety culture from management Road surface maintenance not considered as critical for safety Insufficient Recovery Standards and equipment Standards not established for specific environmental conditions Standards not established for specific equipment characteristics

Level two: Sources of Information Hazards Level three: Causes of Information Hazards Inadequate/no operator communication systems Poor spotter signals . Information or the lack thereof is not generally viewed as a source of hazards Risk of no/poor information not formally assessed Lack of/late ground stability information Information Failure of GPS systems Lack off/late incident information Late/incomplete roads-surface and gradient condition information

Level two: Sources of Environmental Hazards Causes of Environmental Sudden Flooding Level three: Causes of Environmental Hazards Fall of Ground Lightning Dust Environment Rain