Every company must ensure that the production process proceeds without interferences. Within this article, the author uses the term “interferences” in reference to unplanned stoppages caused by breakdowns. Unfortunately, usually due to machine operators’ mistakes, machines break, which causes stoppages thus generating additional costs for the company. This article shows a cause and effect analysis of a breakdown in a production process. The FMEA as well as quality management tools: the Ishikawa diagram and Pareto chart were used for the analysis. Correction measures were presented which allowed for a significant reduction in the number of stoppages caused by breakdowns.

The article concerns the condition of automation and robotization of underground mining in Poland. Attention has been focused on the specific character of the mining industry. This limits the possibility of using robotization, and sometimes even the mechanization of certain processes. In recent years, robotic and automated machines and machine system solutions have been developed and applied in Poland. They are autonomous to a various degree, depending on the branch. The type of automation and artificial intelligence depends on the specific use. Some examples presently being used include the MIKRUS automated longwall system and autonomous device(s) for breaking rocks or mining rescue work. In Poland, fully automated plow systems produced by foreign companies are also used. Companies in Poland and international research centers are also actively engaged in the development of underwater and space mining. where robotization is of key importance. Research is also being undertaken by Robotics in Mining, euRobotics and PERASPERA as well as Space Mining Conference.

Failure frequency in the mining process, with a focus on the mining machine, has been presented and illustrated by the example of two coal-mines. Two mining systems have been subjected to analysis: a cutter-loader and a plough system. In order to reduce costs generated by failures, maintenance teams should regularly make sure that the machines are used and operated in a rational and effective way. Such activities will allow downtimes to be reduced, and, in consequence, will increase the effectiveness of a mining plant. The evaluation of mining machines’ failure frequency contained in this study has been based on one of the traditional quality management tools - the Pareto chart.

The mining organ of the longwall heading machine KGS-320 with radial tools was the subject of the analysis. Cooperation of single knife with the mined solid rock was estimated in order to determine values of the forces and moments that might occur in the mining process and to estimate the energy consumption of the mining process. Analogous determination of forces and moments values as well as energy consumption of the mining process for the whole mining organ with regard to all the knives installed. Following the thorough analysis of the solid rock mining process with the longwall tumble heading machine mining head the PC computer program simulating such organ’s mode of action has been developed. This program presents the simulation of the mining process in the part regarding direct contact of the cutting tool (knife) with the rock mass. The result of this simulation is force and moments distribution, which are transmitted via the mining organ (head) during one full turn (360o) and, as consequence, via whole longwall heading machine.