MMG generates great returns by focusing on continuous improvement
MMG chose AVEVA for their asset utilization program as they were looking for a single vendor for this critical turn-key project
The solution delivered by AVEVA included everything from software, licensing and support, through to business consulting, solution design, implementation services, documentation and user training.
With change management being such an important part of the asset utilization program it was imperative that the project commenced with a business consulting exercise. This discovery services study (DSS) delivered a thorough understanding of the business requirements before any engineering began.
The asset utilization solution implemented at MMG has taken the old OEE lag indicator to a real-time lead indicator. All required data is captured from existing instrumentation and control system, and calculated and presented as easy understandable information to operators. This improved visibility helps Operators to optimize the process on the fly, enabling them to run just below the point of failure at the maximum sustainable rate. This has resulted in measurable OEE improvements, a significant increase to production and a reduction in operating costs
One of the key challenges to the project success was determining the correct positioning of reporting points. Given that a complex process seldom experiences a total loss right across the operation it was important that any stoppage or compromize in production was recognized at the relevant constraint point when calculating the OEE of the overall asset. This meant that it was imperative to achieve the appropriate level of automated data capture at the instrumentation and data collection layers. This challenge was overcome using the results of the DSS.
The project was underpinned with a good change management approach which also included role-based training.
Goals
- Implementation of a standardized Asset Utilization solution across all operational sites globally.
- Achieve ongoing measurement, analysis and reporting of production losses due to equipment utilization.
- Ability to perform root-cause analysis of “less than perfect” utilization of equipment assets.
- Complete integration with other systems to enable “single sign on”.
- Defining the maximum sustainable rate for processes, which may differ between sites.
- Achieving the appropriate level of automated data capture at the instrumentation and data collection layers.
- Standardizing time usage model (TUM), cause codes and classification matrix across all 5 current operating sites globally.
- Adoption of the new work practices given the extensive work experience of people within each operation.
Challenges
- The solution needed to be flexible enough to adapt to the local operating conditions of each mine, while also providing a standardized asset utilization data that they could analyze in real-time.
- Had to have the capability to drill-down to the root-cause of any equipment asset that was exhibiting less than perfect utilization, in order to drive continuous improvement through the business.
- Needed to be readily accepted by global users in a single sign-on environment compatible with existing systems
Solutions
- AVEVA™ Production Management
Results
- Significant improvements to productivity.
- Process constraints (bottlenecks) and efficiency gains exposed.
- Clear root cause analysis (native drill down capability) provided.
- Clarity on how to achieve optimum productivity.
- Improvement to assets, resources and processes.
- Increased asset utilization by at least 10% across the sites.
“MMG is committed to improving the roductivity of our operations, illustrated by these record movements in ore mined and continuing improvements in Asset Utilization.”
Andres Michelmore, Chief Executive Officer, MMG Limited
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