Digital Champions in the Mining & Processing Industry€¦ · Centralized data management Client...
Transcript of Digital Champions in the Mining & Processing Industry€¦ · Centralized data management Client...
Digital Champions in the Mining & Processing Industry
Our Digital Operations framework covers all key operations & support functions and technologies in a mine
2
Connected Supply Chain
Smart Operations
Digital Maintenance
Health, Safety, Security &
Environment
Digital Twin Plant Excellence
Digital Support Functions
IT/Technology
Architecture
Digital Capabilities
& CulturePartnership &
Alliances
Governance/Processes
and Data Management
Information
Risk
Management
DIGITALIZATION OF SUPPORT FUNCTIONS
Enablers:
Connected Supply Chain
MetalProcessing
Digital Maintenance
Integrated Planning
Health, Safety, Security & Environment
Digital Mining
Digital Support Functions
Augmented reality
Exploration
Smart Operations
Digital Champions create value through integrated ecosystems with double-digit revenue boosts and efficiency gains
3
Benefits investing in digital technologies and Digital Champion Solutions – Process Industry
13%
Digital Novices vs.
Digitization of product and service offerings1
2
4
5
Leadership in customer-centric solutions
+
7
Near real-time E2E integration & planning platforms
Full vertical integration / MES of manufacturing operations
Digital Strategy & implementation roadmap
8
Digital experts and dedicated training programs
3Management of a partner solution network
6Tech innovations, e.g. Al Solutions, Collaborative Robots
Digital Revenue Increase
2018 - 2023
8%
23%Efficiency Gains /
Cost Reduction 2018 -2023
11%
Digital Champions
Predictive maintenance at downstream process manufacturerS
en
so
r-a
nd
rem
ote
dia
gn
os
tic
s
Remote control towerData collection On site
Fully digitized process
Remote
Mobile information
Pla
nn
ing
Ala
rm
Ma
inte
na
nc
e &
rep
air
A large downstream manufacturer collects and analyzes operational data that allow for predictive maintenance, remote monitoring & digital repairs
14
Smart Algorithms
CLIENT EXAMPLE
Drone and robot technologies are applied to support maintenance processes in the mining and oil & gas infrastructure
5
Best Practice Examples – Digital Maintenance & Repair
Source: Desk research, Client examples, Strategy& analysis
Pic. 2. Drones for Leak detection
Pic. 1. Corroded elements identified
Pic. 3. Maintenance roboter in uses
• Maintenance of assets, e.g. structural
assessment of technical conditions
of various infrastructure elements,
structural alignment validation,
detection of overheating elements and
corrosion
• Leak detection with no ability to see
the leakage on often long- stretching
or difficult-to-reach pipelines
• Engagement of workforce in potentially
dangerous areas posing a significant
health and safety risks
• Drone-borne infrared sensor enable
automation and acceleration of
maintenance issue identification
• The initial assessment and
correction of the situation can be done
immediately based on real-time video
stream and robot tools
Pic. 4. Self driving robot in mining
maintenance
CLIENT EXAMPLE
3. Operations
Mobile solutions for plant operations
1. Maintenance
Mobile Maintenance solutions
4. Engineering
Mobile access to engineering data
2. Turnaround
Special maintenance
Augmented reality solutions have been implemented by a client in the process industry to optimize operations and maintenance
Connect physical assets to digital world
Enable identification of equipment
Receive performance and quality data in real time
Enable equipment alarm settings and remote diagnostics
Enable equipment visibility and location tracking in complex plants
Provide critical service data for equipment
Push work instructions to reduce time and knowhow requirements for service
Establish optimized user interface, task confirmation and service documentation
Objectives of Augmented Reality
Client example
6
CLIENT EXAMPLE
AR Platform Framework
Sub Platform for SAP based AR solutions based on SMP
(SAP Mobile Platform)
SAP/PM PIMS (prod. inf. mgmt. system) DCS (distributed control system) others
Sub Platform for PIMS based AR solutions(vendor tbd)
Sub Platform for DCS based AR solutions
(vendor DCS specific)
others
Interface Interface Interface Interface
Apps Store + Apps
Digital technologies have been implemented to enable mobile communication and AR solutions
Augmented Reality SolutionWireless Plant Infrastructure
AR as a
Global Service
Se
rvic
e
Client example
7
Mobile Devices &
Mobile Device Management
CLIENT EXAMPLE
Overview
• 3D digital asset information data capture by scanning (drones,
autonomous underwater vehicle (AUV) and scanners) and
providing centralized management of all available field data
• Web-based 3D view of site stored in the Single Point Of Truth
database allow for Single Panoramic Images; Walkthrough /
Flythrough; Asset Tagging etc. Siemens software is used to train
its staff for offshore installations using a virtual 3D environment
• The simulator offers a virtual 3D environment of a plant and
provides the opportunity to simulate real-life situations, allowing
workers to see and experience what tasks they need to perform,
and rehearse procedures and workflows associated with any
number of scenarios.
Benefits
• Increased transparency for brownfield works
• Risk mitigation and increased safety
• Operational Cost and Downtime Reduction
• Reduction of maintenance time & cost 8
Global Process leader trains its field operators in a 3D virtual environment to ensure higher safety procedures and reduce operations cost CLIENT EXAMPLE
Advanced MES planning tools integrate and optimize all operations management functions
9
Dynamic detailed planning & scheduling
Business Planning and Logistics
Production Control and Process
Sm
ar
t V
isu
ali
za
tio
n
Asset configuration
Resource availability
Location / track & trace information
Quality / NCM
information
Inventory levels (RM, WIP, FG)
E2E network capacity and availability
Supplier (plan+order)
Process quality
Product quality
Maintenance Management
Sensor/ actuator data
Ve
rti
ca
l In
teg
ra
tio
n
Customer demand
(plan+order)
Horizontal Integration
Sales & Operations Planning
ProductionOperations
Management
QualityOperations
Management
MaintenanceOperations
Management
InventoryOperations
Management
CLIENT EXAMPLE
MES Digital cockpits allow for real time controlling and optimization of operations processes
Collaborative planning solution
CLIENT EXAMPLE
An integrated end-to-end planning is based on a joint platform for all planning-related activities between key functions
CustomerSupply Integrated planning &
execution platform
E2E supply &
demand planning
Integrated planning and
execution along the
value chain
Integration into B2B and B2C
ecosystem (PoS data & public data,
online market places, own apps,
customer ERP integration)
Proactive demand
sensing
Utilization of digital
customer and
configuration data,
sales data, service
needs and external
data
E2E logistics visibility
(Last mile notification,
E2E tracking)
Enabler
E2E data availability, utilization and analysis & efficient IT and data architecture as supply chain support
Integrated material
requirements planning (VMI/
consignment stock, visibility on
inventory)
Vertical integrated
real-time planning
in production
incl. MES
introduction
End-user
Customer
Warehousing
Tier 2 Supplier
Tier 1 Supplier
Production
client
client
client
Service
Dynamic real-time inventory
management for a multistage
SC and warehouse network
Industry case
Globally leading player using cloud
ERP solution to create a supply
chain ecosystem
• Using a cloud collaboration platform to
link all stakeholders from suppliers
through internal operations to customers
• Near real-time feedback on changes in
customer demand or product availability
assessed and communicated along the
supply chain
• Integration with different legacy planning
solutions and logistics platforms
Supplier Production Distribution Customer ConsumerExt. data
sources
Cloud
based
CLIENT EXAMPLE
Live inventory location and stock level tracking & optimization management has been installed to optimize inventor levels
Fully integrating IBM Maximo with the warehouse
management system for seamless workflow and
real time data analytics
Access control
system
Use of RFID / barcode based scanners
for inbound and outbound material
movement, with automated track and
trace capabilities
- Forklifts with scanners which directly receive pick lists
- Rail-guided Very Narrow Aisle (VNA) storage trucks
- Man-to-goods systems (wide aisle Pallet storage,
racking system with bins and cantilevers)
- Goods-to-man system (vertical carousal system)Access control system and
CCTV for monitoring
warehouse and inventory
Monitoring & Surveillance
(Level 2)
Material Inspection &Tracking
(Level 2)
Systems / IT
(Level 3)
Put-away, Palleting, storage and packing
(Level 2)
Maximo – WMS WMS – Resource (Labour / smart forklift)
Create work order Generate picklistReceive picklist by
resource
Schedule
maintenanceFulfil order
1
2 34
Seamless workflow of warehouse processes
WMS
Integration of Maintenance
CLIENT EXAMPLE
PwC Strategy&
Implementation of a Smart Site Management using an Integrated Supply Chain Tower
13
Control Tower activities
• Just-in-time / Just-in-sequence
delivery
• Detailed operations scheduling
(FTEs and equipment)
• Fleet management &
optimization
• Maintenance management
• Dynamic project management
& scheduling
• Big data analytics for
performance data
• Integration of suppliers (incl.
services)
• Optimal on-site routing
• Autonomous operations
(control room)
• Smart site technologies for in-
and outbound logistics
• Automated and fully
transparent tracking
Automated
warehousing
Shipment
tracking
Smart
conveyors
Augmented
picking
Smart
returnable
packaging
Off site
hubs/
terminals
Site pipe management
Automated
loading
and unloading
Mobile
access
ALER
T
Rail yard
management
Site access mgmt.
Off site On site
Autonomous vehicles
Just-in-time delivery
Operations
scheduling
Fleet
management
Drone-based site
measurement
Connected supply chain Control Tower
Track & trace
Customer
Supplier
Tra
ck &
trace
Tra
ck &
tra
ce
Distribution
Production
Flow of goods
Flow of information
Dynamic demand
sensing and integrated
forecasting
E2E supply & demand
planning and
execution
E2E supply chain and
operations visibility
Automated data
analyticsHolistic supplier management and
collaboration
CLIENT EXAMPLE
A best practice IT architecture covers all elements to enable the implementation of digital applications
14
Data sources, physical processes
Users
Access channels
Presentation(view)
End to end security
IT o
pera
tio
ns m
anagem
ent
Analy
tics, B
I and r
eport
ing
Data
retrie
val and a
ggre
gatio
n
serv
ices
Data
retrie
val and a
ggre
gatio
n
serv
ices
Centralized data management
Client management and staff Client service providers
Web browser M-browser Mobile apps E-mail SMS AR / VR
Website Application portals Dashboards Template management
Multi-lingual support UI personalization Content management Channel specific rendering
Monitori
ng
and a
lert
serv
ices
Syste
m
health
dashboard
Tic
ket/
defe
ct
mgm
t.
Configur-
ation m
gm
t.
Loggin
g/
trackin
g
mgm
t.
Ris
k
analy
tics
End to
end
analy
tics
Org
. P
erf
. A
naly
tics
Self-
serv
ice B
I
Syste
m
usage
and p
erf
.
Fore
cast
Capacity
Pla
nnin
g
Busin
ess
report
ing
Fin
ancia
l
analy
tics
Inte
gra
tio
n m
anagem
ent
AP
I
managem
ent
Managed
FT
P
Inte
gra
tion
dashboard
Clo
ud
Inte
gra
tion
pla
tform
Tra
nsla
tion
and E
TL
schedulin
g
Business services / components layer
Client Business Enabling Solutions
• MOM (Manufacturing Operation Management)• Inventory Management • APM• Procurement suite
• Condition Monitoring• Predictive Maintenance• Permit to work• HSE drones
Client General Purpose Solutions
Client business services and administration functions
Endpoint security
Cyber security
Application and data
security
Identity and access
management
Network security
Physical access
security
Data centre security
Security audit and
compliance
Desktop virtualization
Remote access
management
Data Abstraction Layer MDM database Transaction database Process historian Analytics database Audit database Reporting database
Physical IT infrastructure IT applications
Server infrastructure Network infrastructure Peripheral devices Security devices Business applicationsEnabling / shared
system appsIT delivery and support
mgmt. appsIT security apps
• Collaboration solution• Workflow management
• IT service activation• Knowledge management
• Strategy and performance tracking workflows• HR and training solutions• Account and finance solutions• Legal compliance and case mgmt. solutions
• Contract mgmt. solution• Capital – Investment management solution• Risk assessment and management solution
Recommended IT Architecture
CLIENT EXAMPLE
Source: Strategy& analysis
Empowered employees and the right strategy are at the center of digital transformation
“Our company has
flat hierarchies that
facilitate agile working and
quick decision-making.”37%
“We are focused on
providing a digital
customer experience
throughout the
customer journey.”35%
“Our leadership has
a clear digital vision and
strategy for the digital
future and acts
as role model.”34%
“We foster a culture
of innovation with multi-
disciplinary teams.”
“Our employees have the
required qualifications for
the digital future.”
“We have invested
heavily in training
to make our staff fit for digital
transformation.”
27%
26%
Digital Strategy Digital Organization Digital Education
32%
15Source: Global Digital Operations Study, Strategy& analysis
Corporate Digital Vision and Culture