Mining Fixed Plant Performance – Increase Production and Reduce Waste

Across the mining fixed plant from crushers to conveyors to tipplers, etc you need to understand equipment performance in context of products and teams. Understand the process and asset, identify waste loss points, and in efficiencies in the processes.
Stabilise the Production Process – Reduce delays and losses by using Delay Accounting
20% to 30% gains in stable throughput is often possible just by identifying and removing the primary causes for delays and losses.  Whether it be equipment failures, bottleneck congestion, unexpected feed variability or operator missteps, it all leads to production degradation and/or instability. Continuous improvement teams require tools to analyse the most common causes of these delays as well as the locations in the process they are likely to occur:
  • Automatically capture all delays (equipment downtime and slow running processes)
  • Identify the cause and the locations of the delays
  • Classify/categorise the delays
  • Powerful ad-hoc analysis environment for continuous improvement
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One View Across all Your Fixed Plant Equipment Performance to Target
  • Capture all the production, equipment data across all your equipment
  • Capture production loss
  • Capture Causes Interface to existing control equipment from different vendorsInterface to existing SCADA, automation systemsReliable, scalable data capture
  • Requires minimal, or no changes, to control systems
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Optimise the Production Process – Reduce variability and maximise throughput using Advanced Process Control
Connect directly to a wide variety of automation systems and use both real-time and historical data to analyse, identify and model the significant cause-and-effect relationships in a process.  Using Model Predictive Control, operations can realise their full potential by moving the process closer to active constraints — resulting in reduced process variability and increased profits.
  • Reduce standard deviation, usually by a factor of two or greater
  • Increase throughput by as much as 5%
  • Increase process yields from 2-10%
  • Reduce specific energy consumption by 3-10%
  • Reduce waste, reworking, and recycling costs
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Operate to Maintain and Maintain to Operate – Synchronise your Operation
There is a fine balance to be struck between the production and maintenance teams. Too much scheduled maintenance and the production teams have less breathing room for meeting targets. In turn, this may cause the production teams to push the equipment harder resulting in more unscheduled breakdowns. Coming together to understand that fine balance requires a system that employs an effective Time Usage Model in reporting delays.
  • Drill-in analytics identifies bottlenecks and delivers data on stoppages and delays
  • Maximises efficiency of production time by calculating time around utilisation and availability
  • Maintenance can optimise reliability by focusing on highest impact breakdowns
  • Production can focus on projects that addresses the biggest process issues to be addressed
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Optimising Maintenance to Reduce Cost and Maximise Production
Optimise maintenance performance and efficiency through investments in condition monitoring and predictive analytics. Use real-time information on the health and performance of critical assets, giving personnel the insight needed to make timely and informed operational and maintenance decisions.
  • Condition-based Maintenance (CBM) for common assets (pumps, fans, etc)·
  • CBM is rule-based logic where rules don’t change in during operations·
  • Predictive Maintenance (PdM) for critical assets (shovels, trucks, mills, etc)
  • PdM relies on continuous monitoring of assets for advanced problem warnings
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Digitising Maintenance Activities – Automate, Designate and Collaborate
Connect your mobile workforce through digitisation and increase the profitability of your operations. Ensure consistent and efficient execution of best practices by your maintenance workforce through continuous improvement and providing the most relevant information they require at their fingertips, wherever they are and whenever it is needed.
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Proven Increased Equipment Performance
  • Up to 20%  increase  in throughput gain from existing assets
  • Up to 50%  reduction  in plant stoppages and a decrease in cost per tonne of production Accounts for delays in terms of lost time, lost production tonnes and  lost revenue (Dollars)
  • Synchronises to the equipment list with a master data provider, including Schneider Electric’s UAG and SAP PM
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Mining Professional Services for Value Realisation
Augment your internal project capability with proven subject matter experts and engineers who can help you unlock the value within your business and maximise your returns.  AVEVA’s team of experts and our highly qualified partners globally can deliver insights into untapped improvement potential and then apply proven and sustainable technology solutions to these problems where the highest returns can be realised by the business in the shortest time possible.
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Specifications
Type
Scenario
Optimised Scenario
Proven solution for mining customers who are optimizing their fixed plant like Grinding, Conveyors
Industries
Mining
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