Production Optimization - Wonderware...Production Optimization Ampla Downtime facilitates the capture of downtime information, which is an important indicator of production performance

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Production OptimizationDigital Mining Transformation

Confidential Property of AVEVA Group plc.

Ammar Wahab

Global BDM – Mining, Minerals & Metals

Production Planning Vulnerabilities

Some Potential Solutions

Cause Effect

Forecasts• Predictive Analytics

• Feed Grade

• Weather Condition

Equip/Process Failures• Downtime / Delay Accounting

• Predictive Maintenance

Production Loss• Real-time OEE

Ore Grade• Reconciliation

• Quality tracking

Accurate Inventory• Inventory Accounting

• Metal Accounting

Scheduling• Rescheduling

• Optimisation

Teamwork• Digital Workflow

Conformance

To Plan• KPI Analysis

Cost Predictability• Production Accounting

Achieve

Financial

Objectives

Process Stability• APC / Optimisation

• Operator Training

Cause Effect


Example Implementation Sequence of Solutions

STABILIZE










• Optimisation



• Feed Grade




Conformance

To Plan• KPI Analysis Achieve

Financial

Objectives11

1Achieve

Financial

Objectives

Do

Check

Cause Effect



CONTROL










• Optimisation



• Feed Grade




Conformance


Financial

Objectives11

1 2

22 2

Achieve

Financial

Objectives

Do

CheckAct

Cause Effect



OPTIMIZE










• Optimisation



• Feed Grade




Conformance


Financial

Objectives11

1 2

22 2

33

3

Achieve

Financial

Objectives

Plan Do

CheckAct

How? Start with Achieving Financial Objectives

Are you

meeting your

financial

expectations?

Are meeting

production

targets a

challenge?

Are cost

containment

issues a

problem?

Is consistency

of work and

productivity an

issue?

Are your

processes

stable and

predictable?

How well can

you visualize

and monitor

your process?

• Plan/schedule conformance

• Cost control & predictability

• Accurate inventories

• Optimized capacity plan

• Agile schedule

• Production Accounting

• Consumable & cost tracking

• Effective work & task mgmt.

• Operator training

• Downtime management

• APC and Asset mgmt.

• De-bottleneck

• Situational Awareness

• Analytics & Intelligence

• Integrated ops

Asset OptimizationOperational EffectivenessSupply Chain Optimization

Production Optimization

– Stabilise and Optimise your operations

1. Weibull Analysis to define Maximum Sustainable Rates (MSR) • Real Time Productivity

2. Mining Operations Management-• Downtime/ Delay Accounting,

• Production, Metrics and Dashboards

• Energy Management

3. Advanced Process Control• Grinding, Crushing, Flotation, Smelting


• All continuous operations should use production targets based on MSR and not on Demonstrated Rates.

MSR method is least used and often not understood as many processes do not know or have the means to

determine the metric, let alone measure it in real time.

• It is important to know the differences as small improvements at the bottleneck of a process is like a lever

that will produce significant productivity gains.

• The Weibull analysis method is used to determine the MSR of the process. This technique helps to define

what is physically achievable based on quantification of process reliability. It will provide answers to

questions such as:

• Do I have a reliability problem or a production problem?

• What is the MSR of my plant that will improve productivity?

• How are the efficiency and utilization losses impacting my operations?

• What are the asset and process reliability of my plant?

• What is the value and business case opportunity?

• Weibull analysis technique is used to define demonstrated rate and MSR of the process, identifying the

difference between asset reliability and productivity losses. This provides a clear understanding of the

potential productivity improvements, business case and ROI.

Weibull Analysis to define Maximum Sustainable Rates (MSR)

Delta between DR & MSR -

11,660 vs 12,332

Approx 6% improvement

Indicates potential improvement

opportunity of

672 t/shift or

1,344 t/d or

490,560 tpa

Actual Case study for mining operation

Slope of 3 = poor performance

Slope of 6 = good performance

Production OptimizationWeibull Analysis Method

Overview

• Ampla Real Time Productivity (RTP) offer is a packaged

Ampla solution that is pre configured to include all

reporting points, hierarchy and reports to quickly deploy

the offer on top of existing Ampla projects or can be

delivered in the traditional way.

• Aveva’s MES offering Ampla and subject matter

expertise are being used in a new approach that has

taken the old OEE lag indicator to real time lead

indicator.

• The solution utilises the integration of instrumentation

and control systems to provide information to Ampla that

help Operators to operate the process on the fly to run

their plant just below the point of failure at the Maximum

Sustainable Rate (MSR).

Focus On Increasing Productivity

Business Benefit

• High business impact – focus on burning business

issue (constraint) with high visibility & high ROI

within 3 months of deployment

• Rapid deployment model – 2 months from business

requirement definition to installed solution

• Scalable – can extend functionality to cover asset

performance management without any impact or

loss of focus to productivity through the bottleneck.

• Minimal CAPEX – by organically growing the

solution to cover asset downtime minimises CAPEX

and maximises return on investment.

Production OptimizationAmpla Real Time Productivity


Ampla Downtime facilitates the capture of downtime information, which is an important indicator of

production performance and reliability.

Downtime is time during which production has stopped or production is below a specified target

rate. Recording the root cause of production downtime is the first step to reducing production

losses

> Key Functions

• Data collection – Automatic record creation on occurrence of a downtime event or manual entry.

• Editing and validation – Adding of additional downtime details and downtime event confirmation

through the client interface.

• Information view and analysis – Data presentation for analysis.

> Need to understand the root cause of delays for the following reasons

• Delivers the information needed to improve efficiency, optimize uptime, and increase profit.

• Breaks down complex issues into common causes and enables managers to address problems

proactively.

• Identifies the cause and effects of the production process to enable managers to prioritize

maintenance and optimize uptime.

• Enables you to continuously improve in reducing costs and streamlining operations by increasing

visibility in operating process and equipment dynamics.

• Automatically captures downtime events to remove the inaccuracies and inconsistencies of

manual reporting systems.

AmplaDelay Accounting

From: Historian Manual Entry

Loss Events and process data at time of

loss event (for root cause analysis)

To Operations

Constraints, Losses

and Process

Performance

To Business

Improvement

Loss root-cause

analysis

Delay Accounting


Ampla Production generates an accurate and real-time picture of exactly

what is happening during your production process. It does this by

automatically logging all the inputs and outputs of the plant, including

materials, consumables, energy, waste, emissions, reject and product

output.

• Key benefits:

• Generates clear and concise product information that allows for continuous efficiency

improvements, increased production and reduced time wastage, errors and costs.

• Produces powerful production reporting across multiple production lines or plants.

• Compares production lines quickly and efficiently using a data roll-up function.

• Connects seamlessly to existing business systems, which allows for tight integration

with the company’s IT infrastructure.

• Allows quick access to real-time intelligence tailored to your needs anywhere on your

intranet, including:

• Actuals versus targets

• Consumption per unit output

• Emissions and compliance with regulatory restrictions

• Production information grouped by field (for example, shift, crew, product type)

Production Management


Ampla Metrics aggregates data from other Ampla modules to calculate real-time Key Performance

Indicator (KPI) results that accurately reflect the status and trend of production. KPIs focus on efficiency

and effectiveness in production. Digital dashboards present the KPIs to management (and stakeholders)

by using a variety of easy-to-use dials, graphs, and indicators to suit each user’s requirements.

• Key Functions

•Consolidation of reporting across the plant and across the supply chain•Includes Delay Reporting and Metal Balance Reporting

•Custom reports for specific roles within the operations

•Key Performance Indicators (KPI) to track actual versus plan

•Performance analysis to allow for actions and/or business improvement initiatives

• Important to Operations staff because:

• Improves process efficiencies with a real-time overview of production status and trends.

• Presents a real-time summary of current production through a digital dashboard that you can customize to suit users’

needs.

• Allows access to more detailed information through ‘drill-down’ dashboards.

• Uses data, definitions, and values used by other Ampla modules, thereby reducing the time required for

configuration.

• Enables fast and accurate reporting for better business decisions by giving all users access to the same source

data.

• Provides insights into the operational variables that impact operations performance and plans• Gives the planners/schedulers better understanding of cause-effect of operational events

• Used to create tasks and/or action plans to mitigate the unplanned losses that occurred

LIMSMES Delay

Accounting

MES

Inventory

Planning &

Scheduling

Production

Dashboards- KPI’s

- Analytics

- Production Reports

- Asset Performance

- Production Plans

- Logistics

Historian

To Business Users

Examples: Production, Planners,

Schedulers, Maintenance,

Reliability, Accountants, Managers,

etc

Statistical

Mass

Balance

Production Reporting and Metrics

Pag

e 14

“The asset utilization project is already delivering

significant results. We have achieved around 10-20%

capacity improvement globally. Sepon and Kinsevere

continue to operate 12% and 34% above nameplate

capacity respectively, contributing a further 29,422

tonnes of copper production in 2015 compared to the

year ended 2014.’’

Dan Curry, Group Manager Processing Operations

The Company

MMG operates and develops copper, zinc and other

base metals projects across Australia, the

Democratic Republic of the Congo (DRC), Laos and

Peru. It also has significant exploration projects and

partnerships across Australia, Africa and the

Americas.

Case Study Online

MMG OEE Case Study

Case StudyIncrease Production by 10% by Improving Overall Equipment Effectiveness (OEE)

http://software.schneider-electric.com/about-us/success-stories/mmg-limited/

Confidential Property of Schneider Electric

Operations Improvement Enabler for Mining & Metals Industry (100+ sites)

Moranbah North

Kimberley Diamonds

Venetia Diamonds

Voorsped Diamonds

Minas Rio Iron Ore

Rio Tinto Coal (3 sites)

ERA Uranium

WA Iron Ore (15 sites)

Argyle Diamonds

Dampier Salt

Queensland Alumina

Rio Tinto Alcan Gove

Tomago Aluminium

Kennecott Utah Copper

Iron Ore Canada

Townsville Ports

Copper Refinery

MacArthur River Zinc

Newlands Coal

Clermont Coal

WA Iron Ore (9 sites)

Nickel West (5 sites)

BMA Coal (8 sites)

Olympic Dam

Cannington

GEMCO Manganese

Illawarra Coal (3 sites)

New Mexico Coal

Hotazel Manganese

Wambo Mine

Wilpinjong Mine

Coppabella Mine

Moorvale Mine

Bear Run Mine

NARM Mine

Twenty Mile Mine

Sino IronMagnetite

Wiggins IsCoal ExportTerminal

Aditya BirlaNifty Copper

OneSteel Sydney

Sibelco Mineral Sands

Nyrstar Zinc Refinery

Bluescope Mills (3 Sites)

MMG Copper (1 Site)

MMG Zinc (2 Sites)

CBMM Niobium

Vale Iron Ore

Gerdau &

Votorantim

Steel Mills

Impala PlatinumRefinery (SA)Kinsevere Copper (Congo)

Diamond(Namibia)Husab UraniumMine (Namibia)

Bloom Lake Iron Ore

Sesa Sterlite Smelter(Jharsuguda, India)

Sepon Copper(Laos)

Phu Kam Copper-GoldBan Houayxai Gold-Silver(Both in Laos)

Ok Tedi Mining (Copper)Papua New Guinea

China Shenhua Coal

Shanxi Coal Import & Export Group Corporation

Other relevant

companies

Las Bambas Copper(Peru)

AMPLA

Page 16Confidential Property of Schneider Electric |

> Advanced Process strategies target

unit operations delivering less

variability, increased throughput and

consumables reduction

> Big data & Analytics allow process

improvements identifying hidden

correlations

> Real-time data based on current

economic and process conditions,

giving operators the ability to make

informed decisions at an expedited

rate

Leveraging an integrated

and holistic approach for

mineral process optimization

SimSci APC combines a modern and intuitive graphical user interface with a

rigorous and robust calculation engine that reduces variations in the process,

allowing for operation much closer to the operation limits which improves

process profitability

Production OptimizationAdvance Process Control


APC References

• Increased mean bath temperature by 6 oC

(achieved setpoint)

• Reduced bath temperature variability by 39%

• Reduced time of operation in red zone by 52%

• Increased Cu in White Metal by 0.8% (achieved setpoint)

• Reduced Cu in White Metal variability by 32%

The largest copper producer in the world

Advanced Process Control : Teniente

Copper Converter (Highly interactive

process with complex dynamics)

Realised benefits:

Challenges

• High energy consumption

• Interactive process

• Large unmeasured disturbances

• Frequent shutdowns

Benefits:

• Stabilized furnace

• Reduced energy consumption / Increased production

• Optimized Grinding Lines for Maximum Throughput

• Applied Patented Ball Mill Overload Detection Algorithm

• Increased Throughput by 11.4 Tons Per Hour

• Savings: Approximately $1.9M per year

Diversified mining company producing

copper, nickel, aluminum, lead and zinc

Advanced Process Control: Nickel

Reduction 12 Shaft Furnaces

Major supplier of iron ore pellets to

the North American steel industry from its

mines and pellet plants located in Michigan

and Minnesota

Advanced Process Control: Taconite

Production


Contact Information

Ammar Wahab

• Global Business Development Manager

• Mining, Minerals & Metals

• [email protected]

• +61-450576692

mailto:[email protected]

Questions?


Production Optimization - Wonderware...Production Optimization Ampla Downtime facilitates the capture of downtime information, which is an important indicator of production performance

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