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 Human-Centered Design
for Mining Equipment and
New Technology
 Human-Centered Design
for Mining Equipment and
New Technology

By
Tim Horberry, Robin Burgess-Limerick, and
Lisa Steiner
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Library of Congress Cataloging‑in‑Publication Data

Names: Horberry, Tim, author. | Burgess-Limerick, Robin, author. |

Steiner, Lisa J., author.
Title: Human-centered design for mining equipment and new technology /
Tim Horberry, Robin Burgess-Limerick, Lisa Steiner.
Description: Boca Raton : Taylor & Francis, a CRC title, part of the Taylor &
Francis imprint, a member of the Taylor & Francis Group, the academic
division of T&F Informa, plc, [2018] | Includes bibliographical references
and index.
Identifiers: LCCN 2017048091 | ISBN 9781138095144 (hardback : acid-free paper) |
ISBN 9781138095205 (pbk. : acid-free paper) | ISBN 9781315105772 (ebook)
Subjects: LCSH: Mine safety. | Human engineering. | Mining machinery--Design
and construction. | Human-machine systems.
Classification: LCC TN295 .H739 2018 | DDC 622.028/4--dc23
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Contents
List of Tables������������������������������������������������������������������������������������������������������������vii
List of Figures............................................................................................................ix
Foreword....................................................................................................................xi
Acknowledgements................................................................................................. xiii
Authors...................................................................................................................... xv
Glossary of Terms and Acronyms..........................................................................xvii

Chapter 1 Why HCD for Mining Equipment?....................................................... 1

1.1  verview....................................................................................1
O
1.2 What Is HCD?............................................................................1
1.3 Application of HCD to Equipment and New Technologies
Used in the Minerals Industry���������������������������������������������������2
1.4 Key Points of HCD.....................................................................2
1.5 The Benefits of HCD . . . and the Failures of Not Taking
a Human-Centered Approach����������������������������������������������������3
1.6 HCD Use Scenarios in Mining and the Minerals Industry.........7
1.7 HCD Example: The Need for HCD to Help Develop
Self-Escape Technology������������������������������������������������������������8
1.8 Structure of the Book................................................................. 8

Chapter 2 Principles, Processes, and Tools for HCD........................................... 11

2.1 Overview.................................................................................. 11
2.2 Key Principles of HCD............................................................. 11
2.3 HCD Processes......................................................................... 12
2.4 HCD Data and Tools................................................................ 16
2.5 Summary of the Essential Principles, Processes, and
Tools for Mining HCD............................................................. 18
2.6 Mining HCD Example: Adequate Underground Lighting....... 19

Chapter 3 Current Status of Mining HCD........................................................... 21

3.1 Overview.................................................................................. 21
3.2 How Much Mining HCD Has Previously Been
Undertaken?.........................................................................21
3.3 Mining HCD: Who Is Generally Doing What?....................... 22
3.4 Barriers for HCD......................................................................24
3.5 Examples of Successful Human-Centered
Design Initiatives.................................................................. 27
3.6 Mining Example: Developing ­Self-Escape Technology
with HCD.................................................................................. 36

v
vi Contents

Chapter 4 HCD Educational Material.................................................................. 37

4.1 Overview.................................................................................. 37
4.2 How to Undertake HCD........................................................... 37
4.3 Educational Guide for the 11 Different HCD Activities.......... 39
4.4 Summary of HCD Activities.................................................... 65

Chapter 5 HCD Case Studies............................................................................... 71

5.1 Overview.................................................................................. 71
5.2 Case Study 1: HCD with Underground Loader
Automation at CMOC Northparkes, Australia......................... 71
5.3 Case Study 2: Sandvik Miner Bolter 650.................................80
5.4 Case Study 3: Dust Suppression Hopper
Implementation (Case Study Cowritten with Jessica
Merrill, NIOSH PMRD).......................................................86
5.5 Case Study 4: Interface Design for Haul truck Proximity
Advisory Systems.....................................................................90

Chapter 6 What Now for Mining HCD?............................................................ 105

6.1 HCD Analysis: What Works?................................................. 105
6.2 Automated Mining and HCD................................................. 106
6.3 How Does Human-Centered Design Relate to
Human Systems Integration?.................................................. 107
6.4 Overall Conclusions................................................................ 108
References.............................................................................................................. 113
Index....................................................................................................................... 121
List of Tables
Table 2.1   H uman-Centered Design Activities.................................................... 13
Table 2.2   HCD Tools for the Minerals Industry................................................. 17
Table 2.3   Analysis and Synthesis of the Key HCD Principles, Processes,
and Tools Available for Mining Equipment and Technology
Development....................................................................................... 18
Table 3.1   Mining HCD Barriers Identified by Horberry et al. (2011).................25
Table 3.2   Analysis Results: Four Categories of HCD Barriers and
Examples for Each Category...............................................................28
Table 4.1   Recommended Mining HCD Summary Report Template..................64
Table 4.2   Summary of the 11 HCD Activities for Mining Equipment/
Technologies........................................................................................ 65
Table 4.3   The 11 HCD Activities for Developers of Mining Technologies
and Equipment.................................................................................... 67
Table 4.4   The 11 HCD Activities for Regulators, Mine Site Managers and
Procurement Managers....................................................................... 69
Table 5.1   Comparison of Northparkes Case Study Observations with the
11 Possible HCD Activities................................................................. 78
Table 5.2   Comparison of Sandvik MB 650 Redesign Case Study with the
11 Possible HCD Activities................................................................. 85
Table 5.3   Comparison of the Dust Suppression Hopper Case Study with
the 11 HCD Activities......................................................................... 91
Table 5.4   Comparison of the Interface Design Work for Haul truck
Proximity Advisory Systems with the 11 HCD Activities................ 103

vii
List of Figures
Figure 2.1   E xample of a device design life cycle showing the FDA’s
accepted medical device design process and where
human factors can support this. (Adapted from Human
Centered Strategies, Human Centered Design, www.
humancenteredstrategies.com/process.php, 2006)............................ 16
Figure 3.1   Experiments with bolter controls...................................................... 23
Figure 3.2   Example of a shovel........................................................................... 29
Figure 3.3   Example of developing effective self-escape
technology using HCD-style approaches. (Adapted
from Human Centered Strategies. Human centered design.
www.humancenteredstrategies.com/process.php, 2006.)................. 36
Figure 4.1   Life cycle of mining equipment........................................................ 38
Figure 4.2   HCD activities at different stages of the mining equipment
life cycle............................................................................................ 39
Figure 4.3   Activity being undertaken and injury mechanism for injuries
associated with underground coal bolting machines at US
coal mines......................................................................................... 42
Figure 4.4   Joy Global longwall, including powered roof supports..................... 47
Figure 4.5   (a–c) Walkway cover plates............................................................... 48
Figure 4.6   Roof bolter control design................................................................. 50
Figure 4.7   Assessment of the location of controls for a proposed dragline
seat prior to its installation................................................................ 50
Figure 4.8   A prototype proximity detection system........................................... 52
Figure 4.9   (a and b) Examples of manual tasks in mining................................. 53
Figure 4.10 Manual task risk assessment of secondary support installation
using a jackleg drill (ergoanalyst.com).............................................. 53
Figure 4.11 VDV(10) vs RMS values for each of 70 long-duration,
vertical, whole-body vibration measurements taken from
dozers during normal operations. Data from the same
dozer on different shifts indicated by symbol. Measurement
duration ranged from 140 to 660 min; median measurement
duration = 440 min..........................................................................55
Figure 4.12 Vertical, whole-body vibration measurements (RMS) over
five-min intervals from the driver of an underground coal
personnel transport vehicle travelling over the same section
of roadway, at the same speed, before and after roadway
maintenance....................................................................................... 55
Figure 4.13 Improved design of access guiderails................................................ 62
Figure 5.1   Surface control room layout. Two autonomous loader operators
are located at the front of the room................................................... 74
Figure 5.2   Autonomous loader workstation........................................................ 75

ix
x List of Figures

Figure 5.3   V ideo feed and “teleoperation assist” window provided to

operators............................................................................................ 75
Figure 5.4   West Wallsend improvements included lighting on access,
rubber floor mats, and handrails....................................................... 81
Figure 5.5   MB 650 #181/182/204 (2010/2011).................................................... 83
Figure 5.6   Semi-automated push-button roof bolting controls employed
on MB 650.........................................................................................84
Figure 5.7   EDEEP process steps.........................................................................84
Figure 5.8   Telescoping spout filling a truck bed (not lowered).......................... 87
Figure 5.9  pDR collecting data for telescoping spout truck loading.................. 89
Figure 5.10 5DT haul truck simulator located in the Centre for
Sensorimotor Performance, School of Human Movement and
Nutrition Sciences, The University of Queensland, which was
employed in the experiments (see www.5dt.com/)............................ 93
Figure 5.11 Circuit driven during each experimental trial...................................94
Figure 5.12 Ring (a) and schematic (b) interfaces indicating the presence of
another truck (unseen) and a stationary light vehicle........................... 95
Figure 5.13 Measures describing cornering behavior when participants
were presented with potential collision collated across seven
corners (1–5, 7 and 9). Error bars indicate 95% confidence
limits. The lower panel indicates the magnitude of pair-wise
differences between conditions and the 95% confidence
intervals of these differences. Confidence intervals that do not
include 0 may be considered to be statistically significant...............97
Figure 5.14 The situation encountered by participants on 4 of the 18 trials
undertaken.........................................................................................97
Figure 5.15 Probability of collision when a stationary light vehicle was
located in front of their truck at the start of the trial. Error bars
indicate 95% confidence limits.......................................................... 98
Figure 5.16 Experienced drivers’ cornering behavior at corners where
collision potential events occurred. Error bars indicate 95%
confidence limits................................................................................99
Foreword
I am very pleased to have been asked to write this foreword for Human-Centered
Design for Mining Equipment and New Technology. This book will most certainly
help the reader to understand the importance of focusing on “the human and the
tasks they do” when designing, developing, and upgrading mining equipment and
the value in using a wide cross-section of inputs, including from the end users, while
going through these processes. My personal passion is improving environment,
health and safety in workplaces—HCD clearly has an important role to play there,
but the opportunities to significantly improve efficiency and productivity are also
evident.
When supplying to a truly global marketplace, Sandvik and other original equip-
ment manufacturers (OEMs) are faced with an enormous challenge just to meet the
large number of different and regularly changing regulations and standards. Meeting
these existing requirements is seen as a “minimum requirement” by almost all orga-
nizations that purchase mining equipment. However, many of these organizations,
often supported or pressured by other external stakeholders, now require OEMs to
go “beyond compliance” and look for innovative ways to produce equipment that is
safer, more environmentally friendly, and more productive. HCD is an approach that
has been used to good effect in other industries, and I hope this book encourages
OEMs and the mining industry to use HCD more broadly.
The mining industry is in a very exciting period of change, and OEMs will need
to be both “forward looking” and innovative to prosper. I believe that using HCD as
part of this change will help move the mining industry to its often-stated vision of
Zero Harm.

Stuart Evans
Head of EHS, Sandvik Group
Vice President EHS, Sandvik Mining & Rock Technology

xi
Acknowledgements
The authors are grateful to colleagues at Monash University, University of
Queensland, NIOSH PMRD, and elsewhere for their assistance. The findings and
conclusions in this book are those of the authors and do not necessarily represent the
views of the National Institute for Occupational Safety and Health (NIOSH), Centers
for Disease Control, USA. Mention of any company or product does not constitute
endorsement by NIOSH.
We specifically acknowledge Jessica Merill who was on a student program at
NIOSH PMRD as the lead writer of the “dust hopper” case study in Chapter 5. We
also acknowledge Danellie Lynas from the University of Queensland as a co-author
of Section 4.3.4.6. The content for the book was largely from two research projects:
‘Establishing a Human Centered Design Approach for Mining Technologies’ ­contract
number 200-2014-M-59067, and ‘Human Centered Design Case Studies,’ contract
number 200-2015-M-6294 with the Centers for Disease Control and Prevention,
USA. In addition, the proximity detection case study arose from Australian Coal
Association Research Program (project C24028). We thank the AusIMM for giving
permission to reproduce a conference paper about underground loader automation
at CMOC Northparkes we previously published in the 13th AusIMM Underground
Operators Conference 2017. We also acknowledge other relevant research funding
received by the authors from NIOSH PMRD, the European Commission (Marie
Curie Fellowships), EMESRT, CRC Mining, Australian Coal Association Research
Program, and Coal Services Health and Safety Trust. Finally, we extend our greatest
thanks to our families for their continuing support.

xiii
Authors
Professor Tim Horberry leads the human factors team at Monash University
Accident Research Centre in Australia. He recently was a senior visiting researcher
on a “safety in design ergonomics” Fellowship at Cambridge University in England.
Tim’s background is in human factors, safe design, and transport/mining safety.

Professor Robin Burgess-Limerick is a professorial research fellow at the Minerals

Industry Safety and Health Centre, Sustainable Minerals Institute, The University of
Queensland, Australia. Robin has been a qualified ergonomist for over 20 years,
and is a past-president and fellow of the Human Factors and Ergonomics Society of
Australia.

Dr Lisa Steiner is associate director of science at the Pittsburgh Mining Research
Division at the National Institute for Occupational Safety & Health, Pittsburgh, USA.
Lisa has a background in industrial engineering and has over 20 years of ­experience
in mining and ergonomics. She completed her PhD, “Reducing Underground
Coal Roof Bolting Injury Risks through Equipment Design,” at the University of
Queensland, Australia, in 2014.

xv
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