Integrated Production DashboardNeed of the hour for mining clients – PoV

Author – Prangya Mishra , MES Consultantpswarup.Mishra@gmail.com

A typical mining OT application Landscape

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Planning

Measure

Control

Report

Non – Exhaustive & Illustrative

Opportunity Threats

Strength Weakness

Typical mining OT Application Landscape – SWOT Analysis

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⁻ Multiple Vendors and multiple Applications⁻ Functional Overlapping between applications⁻ Non standard & site specific system implementation⁻ Users have to navigate between systems for required

information⁻ Data aggregation from different sources time consuming, error

prone and complex⁻ Non availability of an Enterprise Data Warehouse and

collaborative planning & decision making.⁻ Non availability of group level reporting for supply chain

monitoring, performance bench marking and comparing performance against competitors

⁺ Infrastructure availability has substantially improved over the years

⁺ System stability and reliability has become reasonable⁺ User maturity level has become realistic over time ⁺ Most COTS applications in the landscape are SOA ready

⁺ Centralized view of data at the corporate level⁺ Integration of data from various sources and without COTS

system vendor involvement⁺ Single source of data for all requirements including analytics and

collaboration⁺ Data quality by standardizing the ETL process across sites⁺ Provide users an ability to complete ad hoc reporting on reliable

data source to help explore the “unknowns” within the business

⁻ Increasing cost of system upgrades and adding new functionality to existing systems

⁻ Increasing risk of falling behind the competitors in the ability to measure and monitor supply chain performance due to lack of integration between the applications

⁻ Increasing risk of inability to create a performance benchmark against competitor and industry standard due to lack of integrated information from various sites

⁻ Loss of agility due to non existence of a common collaboration platform

How an integrated Production Dashboard can help mining clients

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What HowWhy Who & When

Plan, Track & Trace Horizontal D

rill Do

wn

Navigate across the mining value chain to understand and respond to

what; why; how; who & when

Drill down along the vertical to reveal the

specific detail within

the value chain.

An integrated production dashboard helps in revealing the full story lines for the problem areas and issues by linking activities across the enterprise with sufficiently large details across any vertical area within value chain in an intuitive user interface and in real time. Integrated production dash board helps encourage a collaborative planning and operations monitoring environment.

How an integrated Production Dashboard can help mining clients

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Production Area

Fleet

Vehicle

Production

Mine Develop

Maintain

Cash

Power

Consumables

Parts

Labour Hierarchy

PhysicalHierarchy

ActivityHierarchy

Resource Hierarchy

Different hierarchies of enterprise objects are made which relate to each other - for example, in different areas of production, particular activities will occur which in turn consume specific resources. In other words different hierarchies correspond to each other

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Production Dashboard

What it is

A structured database with a relational model that

supports the entire display and report-ability to managecontinuous operations

An unstructured database for direct data storage

and unprocessed "raw" from relevant sources that allowsapplying big data techniques (optimization, predictivemodeling, simulation, data mining, statistics minimum) inorder to have greater understanding and knowledge of theoperations behavior and identify patterns to be preparedfor unwanted situations or exploiting opportunities for topperformers.

Data integration and services based on a SOAlike architecture that facilitates access from this

system to systems data sources of unit operations.

Intelligent layer based on simulation engine,predictability, and optimization, to support daily

operational decision making in a timely manner tosynchronize each of the roles of value chain on real-timeand based on aggregate information and/or filtered.

A platform to include support for Collaborative Planning and forms the foundation bolt for

Remote Operations Center.

Production Dashboard

Concept Explained

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Operational Data

Planning Data Business Improvement

Operational Excellence

Non – Exhaustive & Illustrative

Production Dashboard

Framework

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Non - Exhaustive

Remote Operations Center

Collaborative Planning & Operations Management

Collaboration Platform

Global Monitoring

Dispatch Coordination

Production Coordination

Process Coordination

Decision Support System

Transport Coordination

Mining Production dashboard service areas

High level views of operations, KPIs and alerts

Collaboration platform across the enterpriseDecision Support System for four identified service areas of Process, Production, Dispatch & Transport Coordination

Production Dashboard can have three major gears namely Global Monitoring, Coordination Support, Decision Support System & CollaborationPlatform. The Production Dashboard is intended to provide information services across the mining value chain supported up by a collaborationplatform to enable a collaborative planning & operations management scenario for a mining client.

Production Dashboard

Framework Explained Non - Exhaustive

Overview of the process flow sheet of Mine Management, considering external constraint conditions (Ground, Geo mechanics), as well as KPI.

Process CoordinatorOverview of deliveries to plant, extraction, flows in stages, production losses, and delays of equipment in stages and sectors

PlannerAccess to planning , infrastructure (roads, sprints, routes and tracks), and equipment, delays in process, planned arrests and plant status

Maintenance CoordinatorEquipment and infrastructure status and detentions scheduled, matrixes maintenance plans, and implementing recommendation.

AdministratorCenter staff management (attendance, incentives, performance agreements), budget, and monthly indicators

Overview of current state for extraction, processing and loading, management of extraction points, loading and reduction systems

Overview of current state of fleet, real-time haulage and stockpile management

Overview of current state and management of stockpiles, load out bins and TLO operations management

Process Co-ordination

• Collaborative Planning System for the shift / day / month, in order to analyze and evaluate options.

• Redefinition of activities through the stages of the process from point of disruption so as to keep the system balanced and optimized

Production Co-ordination

• Assessment of extraction point change and to interference proceedings;

Dispatch Co-ordination

• synchronization algorithm for the system Interflow and the productive sectors to prioritize the sequence level trips, projected time, Peak and filling and emptying of pits;

Transportation Co-ordination

• Enabling dispatch algorithms to fulfill plant requirements and sustaining KPIs to meet

• Provide viewing portals for each role, which contains the information required to enable them to meet their goals and monitor their KPI• Generate and maintain the information required by each of the "collaborative events" identified for field teams.• Build a knowledge base (and maintain traceability from types of decisions) with the business rules applied to operational decisions with a corresponding

impact and outcome.• Provide viewing portals for each role, which contains the information required to enable them to meet their goals and monitor their KPI.

Monitoring

Coordination Support

DecisionSupport

Collaborate

Production Dashboard

Technology View

Real time KPIs offering a comparison of the actual respect of schedule (actual vs. plan / budget )

Out of the box connectors to obtain information from multiple sources and add it to the Integrated

efficiently and timely

Module that allows validation and error filtering incoming information to the Integrated System

Information aggregation available on systems relevant to the mining operation (Drill & Blast ,

Hauling , Processing, Logistics Management ) across client mining OT application stack.

Integrated global user Interface and work flows that enables collaborative planning and

decision making. Localized interfaces and work flows that integrates to take care of site specific

requirements

Integrated visualization layer to present an overview of the state of the process across

enterprise, which will be used to monitor overall progress and status of the integrated operations by the system

Intuitive interfaces that require minimal or zero learning time for end users.

How an integrated Production Dashboard creates value

Mining Context

Improved data integrity and make data more accessible for timely andaccurate decision making at all levels and across the enterprise value chain.

Fewer man hours required to produce reports and that allows personnel to focus

on more value added activities for the organization.

Maximize sales opportunities by effective supply chain measurement andevaluation that leads to further sales capitalization

Minimize vessel delays and demurrage through enhanced supply chainmeasurement and evaluation

Improved transparency and data gate keeping since the operations reportswill be produced at a single layer rather than from multiple systems across sites.

Ability to monitor and benchmark against the performance of competitorsand the overall industry in key performance metrics

How an integrated Production Dashboard creates value

Cost Benefit

Tangible Benefits

•Current System Up grade Cost Saving

•Resource cost saving for creating ad-hoc reports

•Increased Revenues due to collaborative planning & Management

Intangible Benefits

•Ability to benchmark performance against competitors and industry standard

•Better alignment of sales, operations, maintenance and logistics leading to better adherence to Plans

• Resources utilized for analysis rather than data collection and compilation

•Increased timeliness and reliability of information

UVP

•Single Sign on instance.

•Reduction in monitoring & analysis of various reports

•Well-structured repository for storing Scheduled reports

•Analysis tools for comparison & alarms

•Remote Monitoring of Production environment.

•Reduced training lead time.

About the author

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Prangya Mishra

Mobile: +91-8884287779Pswarup.Mishra@gmail.com

Prangya is a team leader in Accenture Plant & Commercial Services. He is a graduate Mechanical Engineer with ten years

of metal and mining industry experience in production planning and detailed scheduling, MES and SCM. During his industry tenure Prangya worked with various top integrated steel plants in India in roles from shift engineer to DeputyManager in Production Planning and inventory cost control (PPIC) function.

Prior to joining Accenture Prangya has worked In MES space with automation major Schneider Electric, IT major TCS . He has worked progressively at various levels from team member to lead functional architect for implementing manufacturing execution system (MES) in integrated steel plants and aluminum smelter. Prangya has wide knowledge of project and support service experience of Schneider Electric MES product “Ampla”.

In his previous assignments prior to Accenture Prangya lead the team for implementing the first Ampla MES project in India for a top aluminum producer. Prangya is based out of Bangalore and his current assignments includes managing the MES system for three open cast and one UG coal mine for one of the top five global mining company in Australia.