ENTERPRISE WIDE KPI MANAGEMENT - SACAC · The KPI-calculation-maintenance needed to be streamlined! “Please set up the KPI reports on our plant…” “Please add these KPIs….”

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ENTERPRISE WIDE KPI MANAGEMENT

Warren ArmstrongControl Technology SpecialistAnglo American Platinum

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AGENDA• Anglo American Platinum

• Business Challenge

• What are plant KPIs?

• The old-system

• The new-system

• Contextualisation

• Results

• Benefits

• Next Steps

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ANGLO AMERICAN PLATINUM (AMPLATS)

World’s leading primary producer of Precious Group MetalsSupplying ~40% of the world’s newly refined Platinum.

Process Division:14 Mines 18 Concentrators* 3 Smelters 1 Converter 2 Refineries 9 geographic operational areas

* Including managed and non-managed

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BACKGROUND

For 1gm of Platinum Amplats mines 1400 kg of rockMills 600 kg To 80% less than 75 microns (mm)

or 0.075 mm

2013 tonnages100 million mined44 million milled71 tonnes Platinum

Why so fine?UG2 Platinum Group Metal mineral size!

Typically 5 microns

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SO HOW FINE IS BUG DUST?

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AMPLATS VALUE CHAIN

Ore3.2 g/t

Refineries99.9200 %

Smelters2700 g/t

Concentrate125 g/t

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BUSINESS CHALLENGE

The KPI-calculation-maintenance needed to be streamlined!

“Please set up the KPI reports on our plant…”“Please add these KPIs….”

• Creating a new KPI took 30 minutes

• KPIs were difficult to trouble shoot

• 1 site had 9 KPI reports

The one site had 320 unique KPIs, from multiple requests

Multiple configuration linking

With 3 sites to go...

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WHAT ARE PLANT KPIS?

Daily plant health check: (areas, sections, equipment)

Daily, Weekly, Monthly, Yearly aggregations with standard deviations

Optional run-condition

The process engineers on site look after areasKPIs are defined in areas of responsibility

So KPIs change as problems and people change

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OLD-SYSTEM

• Daily Aggregations done in historian (PI Totalizers)• Weighted roll-ups to predefined periods Advanced calculation engine, saving to historian

• Configured in a flat structure of inputs, outputs and properties (PI Module Database)

• 4 calculation instances Running 484 KPIs Using 2969 historian tags From 7409 configuration entries

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OLD-SYSTEM: ORIGINS

This first KPI-system replaced multiple Excel implementations

Needless to say; this grew!–From: 4 reports and 120 KPIs–To: 8 reports and 437KPIs–…

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OLD-SYSTEM: TO ADD ONE KPI

1. Create 2 daily total tags; KPI, Standard Deviation, Weighting?

2. Create 4 roll up tags

3. Create configuration import – 14 items per KPI

4. Create KPI targets in SharePoint list

5. Update Excel report

6. Upload Excel report to SharePoint (Excel web services)

Procedure to add one KPI

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NEW-SYSTEM REQUIREMENTS

• Simplify configuration

• Let the reporting do the aggregations -dynamically

• Have one report

• Get users to start maintaining their own KPI’s

• Maintainable

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DESIGN AND IMPLEMENTATION

• Consult with partners (OSIsoft and Microsoft)

• What has been done elsewhere?

• Long term reporting architecture

• Contextualisation!

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ARCHITECTURE

PI Asset FrameworkPI OLEDB Enterprise

PI Server

Microsoft Analysis Services

Excel PivotTable ReportStores high frequency plant data

Aggregates this to shift or daily data

Plant HierarchyKPI ConfigurationProvider of consolidated data

Data Aggregation to longer time periodsProvides multiple views and filtering capabilities on the data

Report generation and formatting

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CONTEXTUALISATION

• Contextualise enterprise• Structure and Values in

one place• Ad-hoc trends

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CONFIGURATION DEMONSTRATION

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NEW-SYSTEM: TO ADD ONE KPI

1. Create 2 daily total tags; KPI, Standard Deviation, Weighting?

2. Create Elements; KPI, (create Trend, Target only)

3. Check display order

Procedure to add one KPI

Currently 656 KPIs 3 Sites

It took only 8 hours to translate the old KPIs (~450) into the new

system.

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RESULTS

• KPI creation was reduced from 6 to 3 steps

• One report

• Quick rollout (30min for a new site)

• More user control

• Flexible reporting (Period comparisons)

• Quicker access to data

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REPORT DEMONSTRATION

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BENEFITS: AFTER 2 MONTHS

• Improved Maintainability 2 sites added – 8 hours saved 172 KPI’s added – 52 hours saved

• User Interaction Added 10 KPI’s – 3 hours saved Modified 50 – 4 hours saved

• …

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NEXT STEPS

• PowerView in Excel 2013

• Production reports

• Continue rollout

• Office 365, SharePoint and BI in the Cloud

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WARREN ARMSTRONGWARREN.ARMSTRONG@ANGLOAMERICAN.COMCONTROL TECHNOLOGY SPECIALISTANGLO AMERICAN PLATINUM