Jack Steenekamp - Mining Consultancy Services

© 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 productivity has come a far way with technology…..

Crushing Room – Quebec ca. 1900 Screening Room – USA in 20th Century


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


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


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


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


Case Study 2 Results

South African Mining Complex – Bord and Pillar (46 x CM Panels)

Tonnes per Shift


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


ProdNote® Modules


ProdNote® Integration

� No Paperwork

� More Accurate Reporting

� Real Time Status Reporting

� Improved Communication

� Improved Accountability

� Improved Productivity

� Reduced Costs

� Improved Safety


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


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


MOS Planning Board


MOS Close Out Cycle


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

�


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


MOS Meeting Manager


AUTOMATED MOSPeabody Energy Australia

LEVERAGING PRODMATE TO CREATE AN

AUTOMATED MOS


� 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


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


Peabody MOS


Innovative thinking gets the job done!


Questions ...

Jack Steenekamp - Mining Consultancy Services

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