jack steenekamp - mining consultancy services
TRANSCRIPT
© Mining Consultancy Services (Australia) Pty Ltd. 2016
Integrated Production Management
and Monitoring System
© Mining Consultancy Services (Australia) Pty Ltd. 2016 2
Mining Consultancy Services
Mining Consultancy Services (Australia) Pty Ltd
Mining Consultancy Services (International) Pty Ltd
Mining Consultancy Services (Pty) Ltd
“MCS”
BrisbaneJohannesburg
Moscow
� International company with offices based in Australia, South Africa and Russia
� Established in 1988 – 28 years in the underground coal industry
� Pioneered electronic monitoring on underground production equipment in flammable coal mine environments
� Productivity improvement and process management focus since 1980’s
© Mining Consultancy Services (Australia) Pty Ltd. 2016 3
Mining productivity has come a far way with technology…..
Crushing Room – Quebec ca. 1900 Screening Room – USA in 20th Century
© Mining Consultancy Services (Australia) Pty Ltd. 2016
Plan (MOS)
Schedule
#Production
#Tasks
Report
Update
Simulate
Forecast
4
Management System
COMMUNICATE
Actions
KPI
Targets
Measure
KPI
Evaluate
Plan and Coordinate
Process KPI Management
Communication
© Mining Consultancy Services (Australia) Pty Ltd. 2016 5
Integrated Production Management System
Fully integrated and
modular Production
Management System
(PMS) – integrates
with site specific
Management
Operating System
(MOS)
PMS
� Production
� Maintenance
� Downtime
� Uptime
� Task completion
� Supplies
� Check and inspect
� Statutory reports
MOS
� Planning board
� Meeting Manager
© Mining Consultancy Services (Australia) Pty Ltd. 2016 6
Process Monitoring Systems
� Accurate and meaningful analysis of KPI’s
� User friendly and easily understandable information
� Objective and impartial method of analyzing performance
� Reliable and robust data analysis
� Allows holistic management of production process
� Real time or fixed interval reporting
� Easily accessible web based reports
� Integrated mining unit information system
© Mining Consultancy Services (Australia) Pty Ltd. 2016 7
Case Study 1 Results
Metres per week
0.0
50.0
100.0
150.0
200.0
250.0
300.014-O
ct
28-O
ct
11-N
ov
25-N
ov
09-D
ec
23-D
ec
06-J
an
20-J
an
03-F
eb
17-F
eb
09-M
ar
23-M
ar
06-A
pr
20-A
pr
04-M
ay
18-M
ay
01-J
un
15-J
un
29-J
un
14-J
ul
28-J
ul
11-A
ug
25-A
ug
08-S
ep
Date
Metr
es P
er
week (
MP
OH
)
Avg: 76m/week Avg: 157m/week
Me
tre
sp
er
We
ek
Week Ending Date
106% Improvement
ProdMate®
Commenced
Queensland Mine – Longwall Development
Metres per Week
© Mining Consultancy Services (Australia) Pty Ltd. 2016 8
Case Study 2 Results
South African Mining Complex – Bord and Pillar (46 x CM Panels)
Tonnes per Shift
© Mining Consultancy Services (Australia) Pty Ltd. 2016 9
ProdNote® Handheld Device
� Rugged and Reliable
� Easy to Use
� Long Battery Life
� Real-Time Reporting (Wi-Fi)
� Post Shift Reporting (Cradle)
� VoIP Phone
� Camera
� Fits in Your Pocket!
Size125mm x 65mm x
15mm
Weight 280g
Processor
Texas Instruments
OMAP 4430
1 GHz
dual-core
Display4" Touchscreen
800 x 480 pixel
© Mining Consultancy Services (Australia) Pty Ltd. 2016 10
ProdNote® Modules
© Mining Consultancy Services (Australia) Pty Ltd. 2016 11
ProdNote® Integration
� No Paperwork
� More Accurate Reporting
� Real Time Status Reporting
� Improved Communication
� Improved Accountability
� Improved Productivity
� Reduced Costs
� Improved Safety
© Mining Consultancy Services (Australia) Pty Ltd. 2016
LW Development Dashboard
12
MOS - Forecast Production and Tasks/Maintenance etc, Configurable Week and Shift Plan, Resource Planning, Built-in Simulator (automatically updates forecast and plan after each
shift), Forecasts Production and events for each shift and period
Equipment Performance, Downtime Reporting, Supplies Audits and Statutory Checks
Panel Production Diagram showing real time status of:� Production Status (and by crew and shift)� Process Sequence Tasks� Mining Conditions
Production/Operating Time and Operating Rate with
Shift Target Vs. Actual Comparison in Real Time
© Mining Consultancy Services (Australia) Pty Ltd. 2016
Longwall Dashboard
13
Longwall Face Management
LW Management diagram:• “As-mined” gate road rib-side locations• Face creep relative to centre line of gate
(MG, TG or both)• MG and TG chainage position• Face “lead” and “lag” at MG and TG for
face control management
LW Production Status and Task diagram: • Longwall production by crew per shift• Face position at SOS/EOS by shift• Planned Task Observations (PTO’s)
location and measurements/notes• Mining height• Dilution (roof/floor/in-seam)• Roof conditions• Location of geological anomalies on face,
e.g. faults• Sequence tasks and completion status• Data from other information systems also
importable and displayed as required, e.g. gas, air flow
© Mining Consultancy Services (Australia) Pty Ltd. 2016 14
MOS Planning Board
© Mining Consultancy Services (Australia) Pty Ltd. 2016 15
MOS Close Out Cycle
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MOS Meeting Manager
Automated system to manage meeting
structure and outcomes
� Schedule meetings
� Agenda
� Meeting documents
� Previous actions and issues
� Meeting minutes
� New actions and issues and resourcing
� Distribution
�
© Mining Consultancy Services (Australia) Pty Ltd. 2016 17
MOS Meeting Manager
� Auto generated minutes after each meeting and emailed to attendees
� Tasks planned, assigned and resourced
� Actions planned as tasks in planning board module
� All actions and KPI’s logged
� All issues logged, action, managed and escalated if required
© Mining Consultancy Services (Australia) Pty Ltd. 2016 18
MOS Meeting Manager
© Mining Consultancy Services (Australia) Pty Ltd. 2016 19
AUTOMATED MOSPeabody Energy Australia
LEVERAGING PRODMATE TO CREATE AN
AUTOMATED MOS
© Mining Consultancy Services (Australia) Pty Ltd. 2016 20
� MOS implemented at all Peabody underground operations to standardise
information flow and sharing within the business to enable achievement of
business goals in a safe, productive and cost effective manner
� MOS details the disciplined framework incorporating specific work planning,
execution and review processes for all operational areas
� Accountabilities within MOS cascaded to an individual level
� ProdMate® was selected as the tool to help automate the MOS including
� Automated work planning and review - task generation and close out
� Automated data input from equipment
� Automated link between production and maintenance planning systems
� A Peabody mine was chosen as the pilot site for rollout of the ProdMate®
system to ascertain the ability of the system to automate the MOS
Peabody MOS
© Mining Consultancy Services (Australia) Pty Ltd. 2016 21
One Integrated System…
Engineering Work Orders Equipment and Labour Planning
4 Week Forecast
SIC Reporting during
Shift against PlanShift Plan
Shift Planning
Closeout Reports for
Review and Action
Shift Closeout
Auto Task Generation
based on Mine Plan
Peabody MOS
1. INTRODUCE MOS STANDARD
2. AUTOMATE TASK GENERATION (PLANNING FUNCTIONALITY)
3. AUTOMATE DATA ACQUISITION (Closeout Function)
1. INTRODUCE MOS STANDARD
Sta
ge
1
A staged approach is currently being utilised to help entrench and automate the MOS
process at underground operations
2. AUTOMATE TASK GENERATION (Planning Functionality)
Sta
ge
2
3. AUTOMATE DATA ACQUISITION (Close Out Function)
Fu
ture
Sta
ge
3
MES
System
4. AUTOMATE DATA ANALYSIS & DECISION MAKING PROCESS
Fu
ture
(Sta
ge
4)
MES System
data
ACTION
Current Status
4. AUTOMATE DATA ANALYSIS AND DECISION MAKING PROCESS
MES System
data
ACTION
Current
State
Future
State
© Mining Consultancy Services (Australia) Pty Ltd. 2016
Peabody MOS
© Mining Consultancy Services (Australia) Pty Ltd. 2016 23
Innovative thinking gets the job done!
© Mining Consultancy Services (Australia) Pty Ltd. 2016 24
Questions ...