Digital Mining Enterprise (DME): Integrated Application ... · PDF fileDigital Mining...

Digital Mining Enterprise (DME):

Integrated Application Landscape using SAP Solutions

Nikhil Chaturvedi

IBU-Mill Products & Mining, SAP Asia Pte. Ltd.

[email protected]

mailto:[email protected]

© 2012 SAP AG. All rights reserved. 2

Disclaimer

Please note that, in this document, some of the predictions about mining

industry related processes and technology are based upon our current

understanding and foresight. Also, as the predictions relate to a mining

enterprise of future, the long time-span makes visibility and predictability

rather uncertain.

The predictions and future visualization in this document should be treated as

indicative.


Agenda

Digital Mining Enterprise (DME)

Characteristics

Objectives

Dimensions

DME: Application Dimension

Enablement through SAP Manufacturing Integration and Intelligence (MII)

DME: Infrastructure and Connectivity Dimension

CISCO-SAP Collaboration for DME

Prioritized Work Areas

– Remote Operations Centers (ROCs)

– Expert-on-Demand

– Incident Management and Safety


Digital Mining Enterprise (DME): Sneak Preview

Mining operations to be controlled from Remote Operations Center (ROC)

Intelligent equipment have been making decisions based on the real-time

working conditions

Greater involvement of Field Robotics and Autonomous Haulage Systems


Where a particular data gets entered into the “application landscape” of that

mining company only once and…

… is accessible across various other applications and to different people, depending upon:

– Data mapping rules

– Workflow rules

– System authorizations etc.

… is capable of being accessible across various kind of devices like:

– Desktops and laptops

– Tablets

– Mobile phones

– Smartphones

– Handheld devices

– Scanners

– RFID devices etc.

– and any others that may emerge over a period of time

Digital Mining Enterprise (DME): Characteristics


Digital Mining Enterprise (DME): Characteristics (Contd.)

Where the mining organization has

the capability of orchestrating

information systems on-premise

and on-demand with ease and

confidence

Where the system has adequate

flexibility, scalability, security and

interoperability to provide access to

the company data or information to

not only employees, but also

external stakeholders like

customers, suppliers, partners,

regulatory agencies and public at

large - - depending upon the

access authorizations for each

person in specific


Digital Mining Enterprise (DME): Characteristics (Contd.)

Where integration and intelligence are available end-to-end across

various functional areas like:

Mine planning, scheduling and operations

Processing operations: Planning and Execution

Equipment maintenance

Environment Health and Safety (EH&S)

Operational Reporting & Intelligence

Energy Management

Contract-to-Cash

Transportation & Logistics

Procure-to-Pay

Project Management

Financial & Cost Accounting

Human Resources etc.

Focus of today’s

presentation


Digital Mining Enterprise (DME): Objectives

Enhancing Delivered Throughput (Production + Processing + Transportation)

Greater operational efficiency and productivity (taking into account the constraints like

declining grades, inadequate skilled people availability, difficult terrains, greater depths,

higher rock stress, impact on environment)

Reduce the operational costs in Mines and Processing Plants

Reduce the combined Total Cost of Ownership (TCO) of various applications running in

the Mining, beneficiation, processing and transportation areas

Improve collaboration among various functions

Reacting real-time to geological conditions using intelligent and remote-controlled surface

mining equipment AND underground mining equipment

Increase exploration efficiency using Intelligent drilling rigs and improve the quantity and

quality of data acquired from borehole

Have you prioritized the key drivers for your mining organization?


Digital Mining Enterprise (DME): Objectives (Contd.)

Convert the current sub-economic resources to profitable reserves (esp. deep hard-rock

metal resources; near surface radioactive & beach minerals etc. that can not be mined using

current technology)

Increase Overall Equipment Efficiency (OEE) based on Availability, Utilization, Efficiency,

Quality

Creating visibility into the operational and maintenance data

Increase Supply Chain & Logistics Efficiency and Inventory Visibility

Improve safety and environmental compliance

Increase Human Capital efficiency and productivity by freeing up Mining manpower for

more analytical and value-adding roles rather than regular mundane jobs

Providing better working conditions to the Mining employees, often in “Remote Operations

Centers” away from the Mining and processing plant shop-floor, that in turn will help in

attracting and retaining the workforce

Have you prioritized the key drivers for your mining organization?


Connectivity and Infrastructure (esp. in Remote Mine Sites)

Data | Voice | Video

Mesh networks

Industrial Ethernet (Wired) and Wireless

IT Applications (Enterprise apps, Mobile apps)

Usability

Integration

Collaboration

Online and Offline functioning

Operational Technology (OT) and Automation

Mining (including Remote Operations Centers – ROCs, GPS, GIS etc.)

Processing plants

Integration of IT and OT

(Big) Data Management

Rugged Mobile and Handheld Devices

Information Access and Security

Digital Mining Enterprise (DME): How to Achieve it?

Key Dimensions

Digital Mining Enterprise:

Application Dimension


Enterprise

Management

System

Production

Control

Systems

Mining

Specialist

Systems

Integrated

Systems of a DME

Geological

Modelling

Reserve Est.

Mine Design

Mine Planning

Mine Scheduling

Automation

PLC/DCS

SCADA

Data Historian

Plant Execution Systems

Finance & Costing

Human Resources

Materials Management

Plant Maintenance

Investment Management

Logistics Management

Workflow

Quality Management

Environmental, Health & & Safety

Knowledge Management

Business Planning & Consolidation

RFID

Vehicle Dispatch System (incl.

GPS)

Business Intelligence, Dashboards

Mobile Solutions

Business-to-Mining Integration

Weighbridge systems

GIS

Loading systems

Stockpile management and

blending

Mining System Landscape: Myriad of Applications


SAP Solutions for integrated mining supply chain

(Pit-to-Port)

Sales & Shipping

Transport Processing Mining

Production Stockpile Stockpile Stockpile

MES

Real time

18 months

Month/week

Daily

Daily & Shift

Execution

20 years Long Term

Planning (Life of Mine)

Medium Term

Mine Planning

Short Term

Detailed

Mine Scheduling

Sales Forecasting

Integrated Supply Chain Planning

Short Term Processing

Scheduling

Rail & Shipping Scheduling

Rail & Shipping Execution

Short Term Mine

Schedule

Maintenance

Production

Inventory

Costing

Quality Sales &

Invoicing

Stockpiling

Quality

Connectivity & Real-time Visibility: MII, Netweaver PI

Commodity Pricing

Fleet Mgmt. Historian MES

SAP Best Practices for Mining delivers preconfigured scenarios for most areas of the supply chain

SAP ERP /

Business Suite

Partner Products

SAP ERP +

IS-Mining

Maintenance

Production

Inventory

Costing

Quality

Electronic Weighbridges


Integrated Landscape of a Digital Mining Enterprise:

Using SAP Manufacturing Integration & Intelligence (MII)

Production

Planning

Production

Reporting

Maintenance

Management

Environmental

Health & Safety

Quality

Management GLOBAL

COORDINATION

LOCAL

EXECUTION

HQ-to-Mine /

HQ-to-Plant

INTEGRATION

Integration

Enable a

Single Version

of the Truth,

synchronized

operations

Intelligence Empower mine

personnel and

enable real-

time decision

making

Innovation

Deploy new

mining &

beneficiation

processes and

composite apps

Manufacturing Composite Application Services

Process

Automation

Systems

Fleet Management

System (VMS)

Mine Planning &

Scheduling

VIP (Partner Solution)

SAP MII

SAP ERP, SCM, EAM, EHSM D

IGIT

AL

MIN

E

Other Partner Solutions Weigh Bridges

DIG

ITA

L M

INE


Enterprise SAP NETWEAVER

Oth

er

SA

P B

us. S

olu

tio

ns

S

AP

B

/ B

OB

JI

SAP Manufacturing

(SAP ERP)

Manufacturing Intelligence Dashboards

SAP MII

Manufacturing Integration

Manufacturing Intelligence

Manufacturing Integration

PI

• Production Confirmations

• Process Messages

• Material Receipts

• Material Consumptions

• Material transfers

• Inspection results recording

• Quality Notifications

• Batch Characteristic recording

• Work Orders & results

recording

• Maintenance Notifications

SAP MII’s ability to

perform transaction

execution into SAP also

enables automated,

plant-level creation of:

• Planned Orders

• Bills of Material

• Production & Process Orders

• Material Inventory Levels

• Inspection Lots Data

• Master Recipes

• Material Details

• Batch Details

• Resources & Functional

Locations

• Maintenance Work Order &

Notification details

• Material & Order Costs

SAP MII extracts data

from SAP ERP and

provides real-time

visibility and distribution

to Mine / Plant Systems

SAP MII synchronizes Mining & Processing Operations

with the Enterprise, in heterogeneous IT landscapes


SAP MII: Services Based Architecture

Data Services

Real-time integration of data with plant floor systems, applications and legacy systems.

Visualization Services

Extensible presentation layer presented via web pages. Family of configurable UI

objects provide manufacturing views in role based dashboards or via wireless PDAs.

Business Logic Services

Flow based logic engine, enables data aggregation and transformation of disparate

data. Transactions can be triggered or scheduled. KPI Calculations, business rules,

and alerts are easily developed and executed.

SAP MII Data Services

Visualization

Services Analytic Services

SAP MII is a service-based composition environment that leverages unique services for rapid development of Manufacturing Integration and

Intelligence applications across all industries served.

Business Logic

Services

Web Services



Operational Visibility and Control using SAP MII

The real-time visibility of what happens on the shop floor and the

possibility of all those involved in the manufacturing and delivery

process working together is essential to improve processes, reduce

costs and intermediate stock levels and moreover the improvement

in various industry operational indicators.



Operational Reporting and Dashboards using SAP MII

Increased Visibility into to operations and improve decision support

$4-12MM annual (sustainable) savings on energy use per plant



Analytics for Mining and Processing using SAP MII

Manufacturing Analytics (for Mining & Processing)

• Complete SPC analysis suite delivers actionable real time variable and attribute

analysis

• Trending functions enable relation of process analytics to orders, lots or batches

• Drill down functionality empowers users to quickly execute root-cause analysis



Work Process Management using SAP MII

Work Process UI

• Facilitates integrated, automated, safe and compliant execution of all work

process steps along execution.

• Out of the box templates for easy adjustments and maximum adaptation

• Built in integration to SAP Business Suite avoids data duplication and provides

lowest TCO



Multiple-level Performance Management using SAP MII

Configuring the Views • Wizard to ensure consistency • Templates to simplify

configuration, drive consistency

Multi Site Performance Overview • High level view of multiple facilities • Integrated with corporate and supply chain

performance metrics

Site Performance Overview • Key metrics for primary areas • Raw, WIP, finished inventories • Key unit metrics – throughput, yields • Overall Equipment Effectiveness KPI’s • Asset Utilization KPI’s • Compliance KPI’s

Area Performance Overview • Key indicators for each area • Top items of interest by area – not all details • Identify key trends, forecasts

Production Performance Detail • Single asset/single issue root cause analysis • Production inventories / projections planning vs. actual key quality, yield forecasts

• Equipment / Machine Process overview graphic


Integrated Short-Term Mine Scheduling Process

SAP ERP Mining Dynamics SAP MII Mining Production

Systems

Geological

System SAP BW

Mine

Model Detailed

Scheduling

Output :

Material

Quantity

Quality & Dates

Eq usage

Consumable

Usage

Utility Usage

BOM & Recipe

Input / Output

Resources

Utilization

Production

repository

Preventive

maintenance order

and planned

shutdown for

equipment

SAP Enterprise Portal Reports/KPIs (e.g. Plan v.s Actuals)

> Day/Shift

Last week’s/day’s

production

Fleet Management

Production Actuals

Runge’s Production

Planning & Scheduling

Mine Production

Execution

Master Data (e.g.

equipment,

capacity, cost rates)

Process Order

Real-time Reports

Create Confirmation

Actuals validation

Consolidate data from

ERP required for

scheduling

Plan validation

Create Process Order

Manage updated

version of the plan

Fleet Management

Schedule

Bring latest version of

the planned output

Manage plan change

request

No

Yes

Yes

Dispatcher Production Supervisor Truck Operator/Truck VIMS

VMIS/PCS

Record 1 of Truck1

Shift Report

Confirm

Process Order

VMIS/PCS

Record 1 of Truck2

Display of Truck2

Schedule/

Reschedule

VMIS/PCS

Record 2 of Truck1

Display of Truck2

Schedule/

Reschedule

VMIS/PCS

Record 2 of Truck2

Display of Truck1

Display of Truck1

Schedule/

Reschedule

Schedule/

Reschedule

Actual quantities per truck for current shift

Approve

Yes

No


Integrated Short-Term Mine Scheduling Process


Integrated Truck Maintenance Process: EXAMPLE

Dispatcher Maintenance Supervisor

& Planner Truck Operator

Notices Engine

Problem

Records

Engine Problem in

Fleet Management System

Create Work Order

Workorder confirmation

Production Supervisor &

Planner

Reschedule

Working Day based

on scheduled

Downtime

Reschedule

Available Fleet

Alert about Downtime Start

Automatic Record

in Fleet Management System

Alert about Downtime End

Automatic Recrd in

Fleet Management S.

Create Notification

in SAP System

Analyses problem on site:

Equipment Breakdown

due to Engine Failure

Work Order

Processing

incl. Planned Duration

ALERT into Dashboard

about

Equipment Breakdown

Update of Integrated

Production Plan based on

latest Equipment

Availability Plan

ALERT into Dashboard

about

Equipment Breakdown

END


SAP

Plant Connectivity

Digital Mining Enterprise: Processing Plant

Enablement through SAP MII and Plant Connectivity (PCo)

SAP MII

Dashboard

Further

processing in ERP

Historian

SCADA

MES

LIMS

• Event trapped and

validated against

trigger criteria.

• Custom Notification

created and dispatched

to Destination.

• MII processes the event

message received from

Plant connector (PCo).

• All SAP MII capabilities

like dashboard, alerting or

further process trigger can

be enabled

Alerts etc.

Standards: OPC DA / AE / UA /

Socket

UDS


Mine planning and

scheduling

Fleet Management

Metallurgical

reconciliation

CAT Minestar

Downtime

Recording

Reliability Centered

Maintenance

Asset information

management

IVN Facilitator

Implementation Partners

Mining Industry Council

Infrastructure and

Connectivity

Industry Value Network (IVN) for Mining Driving co-innovation with our customers & partners

http://www.osisoft.com/

http://www.citect.de/?p=2751

http://www.deloitte.com/dtt/home/0,1044,stc=HOME&lid=1,00.html

http://en.wikipedia.org/wiki/Image:Rio_Tinto.svg


Infrastructure and Connectivity

Dimension

CISCO-SAP Collaboration Project


Minimize risk & Maximize Security

Increase Asset Utilization

Support Environment & Regulatory Compliance

Maximize Employee Productivity

Improve Operations Management

Expand Visibility into Operations

Connected Mining Benefits


CISCO Converged Plant Wide Ethernet ( CPwE) Architecture Industrial Networking

Customer Challenge

Multiple and disparate networks exist in many mining operations and there is growing

demand to integrate the networks to provide increased end to end visibility into the

production operations for the following reasons:

Increase of cyber threats for process control systems.

Abundance of COTS – Tools, Patches - All add to risk of security breaches

Increased demand to securely link operation and corporate networks.

Requirements for remote access, real-time, visibility, and post incident analysis.

Ability to capture forensic information to help troubleshooting and improve real-time decision making.

Optimize enterprise-wide operational performance and efficiency from disparate systems


Tracking & Scheduling Logical Overview

Voice Video Data

Printer

PDA

GPS

DVR

Laptop

Video Cameras 2.4, 4.9GHz, or 5GHz

Uplink to Mesh Infrastructure Or 3G Cellular

Wireless Handset – ATEX (Zone 2/ 22) & CSA – IP64 Approved (7925EX)

Laptop

By utilising a unified standards based IP infrastructure

You can leverage multiple applications and services..

Improves:

• Operations

• Maintenance

• Safety

• Logistics

http://images.google.com/imgres?imgurl=www.directlvs.com/Camera/JVCP/Photos/tkc750u_lg.jpg&imgrefurl=http://www.directlvs.com/Camera/JVCP/Specs/tkc750u.htm&hl=en&h=225&w=300&start=58&prev=/images?q=Surveillance+Camera&start=40&svnum=10&hl=en&lr=&ie=UTF-8&oe=UTF-8&sa=N

http://www.usa.canon.com/html/conCprProductDetail.jsp?modelid=6620&item=6630&section=10215


http://images.google.com/imgres?imgurl=www.galactek.com/hnaweb/images/pda.gif&imgrefurl=http://www.galactek.com/hnaweb/&hl=en&h=254&w=161&start=13&prev=/images?q=PDA&svnum=10&hl=en&lr=&ie=UTF-8&oe=UTF-8


O

Win 2008

PI Interfaces

ISR-G2

Vmware VM’s

SRE-V /UCS-E

Win 2008 Sharepoint/Office

PI Server /Notifications

UCS-C/B

PLC/SENSORS

Remote Location Telemetry Aggregation via ISRG2/UCS-E

Hosted VM’s IE3000

IP Telemetry Asset

Win 2008 PI AF Server Process Book

Cisco Industrial Switches

Borderless Network

WAN

Public/Private Cloud

Remote Asset Asset Central Control Room

Control Engineer

On site Engineer

PI Visualisation tools

Example IWE Workforce Enablement channels

PI application and database Hosting on UCS

‘CEBT’

Collaboration Enabled Business Transformation

Business Process Logic

Application

Other Delivery Channels

Assets


Connected Mining A Solutions Approach of CISCO

Customer Challenges

Solution Requirements

Engineering Design

Integration of Technologies

Validation & Implementation of Solution


Prioritized Work Areas for CISCO-SAP Collaboration for

Mining Industry

1. Remote Operations Centers (ROC) enabled by CISCO infrastructure

AND SAP Manufacturing Integration & Intelligence (MII) solution

2. “Expert-On-Demand” solution using:

• CISCO’s “Remote Expert” (an umbrella solution with components like

Telepresence, Jabber, QUAD etc.)

• SAP HCM, Maintenance, Visual Enterprise solutions

3. SAP Incident Management enabled through CISCO Infrastructure

1. Remote Operations Centers (ROC)

Enabled by:

• CISCO infrastructure AND

• SAP Manufacturing Integration & Intelligence (MII) solution


Digital Mining Enterprise: SAP Mobility with CISCO Infrastructure for Mine Equipment

Central Planning and monitoring Mine Site

SAP Business Suite SAP NetWeaver®

Central

SAP

Mobility

Server

satellite and GPRS

feeds

SAP

Mobility

running on

vehicle

CISCO

communications

equipment

running on

vehicle


Video Wall – Remote Operations Centres SAP MII with CISCO

CISCO delivered live video feeds CISCO infrastructure collecting and

communicating sensor information

Collection

Aggregating information from various Sensors / Plant Automation systems and

transferring to SAP solutions using CISCO’s infrastructure (routers, switches, Digital

Media System-DMS, UCS etc.).

Visualization

Video Wall and individual PC production data visualization delivered using SAP MII and

Business Objects


Tracking & Scheduling Mobile Equipment

Operational Efficiency

Operations Safety

• Scheduling Applications • Production Accounting

Maintenance

• Pro-Active & Predictive Maintenance

• Video Services • Expanded visibility for

truck drivers

Logistics

• Traffic Control • Locations based

services (GPS)

• Reduced costs for incidents and unexpected shutdowns

• Improves operational efficiency and productivity

• Increased worker productivity

• Better Visibility into Supply Chain


For underground and open cut

mines, having flexible / mobile

control rooms and video

conferencing facilities is ideal.

The Video Wall picture on the

last slide would ideally be

displayed in the container.

The mobile control room can

also have quick access to

teleconferencing facilities.

SAP MII with CISCO Solutions for Mobile Control Room


Bring a space optimised, ruggedized

“Kiosk” into crib rooms to provide

interactive services for:

Human Resources services from

SAP

Blasting times

Safety messages from SAP

Production plans and actuals from

SAP

Maintenance events from SAP

Shift status reporting from SAP

Delay accounting

… using CISCO’s Infrastructure

for data and video feed

SAP MII / Business Objects with CISCO Solutions

for Crib Room Services

2. “Expert-On-Demand” solution

Enabled by:

• CISCO’s “Remote Expert” (an umbrella solution with components like Telepresence,

Jabber, QUAD etc.) and

• SAP HCM, Maintenance, Visual Enterprise solutions


Inspection Operator sees corrosion, uncertain if it is a real problem…uses mobile communicator to find expert…connects call

Cisco 7925-EX or

Smart Phone

Integration with UC

and Mobility

Video Equipment Inspection Based on: Field Mobile Video service

Upload to Cisco Webex

Social for Show and

Share - Replay Voice &

Video for knowledge

transfer

Value

• Reduced time to evaluate critical and non critical issues

• Reduction in downtime due to better decisions and leveraging remote experts

• Reduction time to intervention on drilling * avg cost/hr of drill rig

• Reduction of risk of incidences vs. average cost per incident

Cisco Cius (Not

ATEX Rated)

ATEX/CSA rated

(zone 2)

… Using hand held wireless EX camera, has collaboration session with experts, recording where needed


SAP Mobile Solutions with CISCO for Maintenance and Production

Embed CISCO “voice calling”, “video feed”

and “CISCO Webex social networking

functionality” into SAP Syclo Mobility

solution for access to expert-on-demand

for:

1. Visual Inspection and advice

2. Maintenance Processing

3. Production scheduling

3. Mine Safety solution

Enabled by:

CISCO Infrastructure and

SAP Incident Management


• Regulatory Compliance (Safety, Labour, Environment)

• Reduced costs for incidents and unexpected shutdowns

• Improves operational efficiency and productivity

• Increased worker productivity

Connected Mining Information System Collaboration & Visibility

Safety & Operational Efficiency

Corporate Messaging Point of Use

• Executive announcements

• Company Information

Live Video

• One to many Messaging & Video e.g. Entertainment

• Safety Warning’s • Production Data, Status

& Statistics

Video on Demand

• Operational procedures (Set-up)

• Training

Thank you

Contact information:

Nikhil Chaturvedi

Director, Global Lead – Mining, IBU-Mill Products & Mining

SAP Asia Pte. Ltd., Singapore

+65-97393866


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