Gawie Reyneke MESA Africa Conference Presentations 2016 - 16 Nov

Mastering the Fourth Industrial 

Revolution – Smart MOM 4 Industrie 

17/18 November 2016 

Operational Management Systems In The 

Mining Environment 

Gawie Reyneke 

Do you know MESA?

Agenda 

• Lonmin 

• Where did Lonmin OMS start 

• System Framework and Modules 

• LoT & Integration 

• System Acceptance 

• Conclusion 

50 Shades of MOM| ©2015, MESA International 

2 

The power of knowing what MESAKNOWS

Company Background 

Lonmin is listed on the stock exchange in 

London and Johannesburg. The company 

engages in the discovery, extraction, 

refining and marketing of platinum group 

metals and is one of the world’s largest 

primary producers of PGM’s 


3 

The power of knowing what MESA KNOWS

Introduction 


4 


Journey 

Where did it all Start? 


5 


Metals Accounting 

• Principles of System 

– Common across the business in South Africa and London 

– Web based and accessible from any internal web location 

– Architecture that allows for easy storage, search and 

retrieval of information. 

• Common data warehouse 

• One version of the truth 

– Single point entry of data 

• Quality control at source 

• Eliminate spreadsheets as repository 

• Eliminate data re-entry and manipulation 


6 


MII 

MII 

Original Architecture 

OMS 

Integrated Objects 

Wonderware 

ArchestrA 

CSense 

MII 

Central Production 

Repository (S95) 

Mincom 

MII 

Portal 

Concentrator 

Control Systems 

Raw Data 

Non Validated 

Transactional & Batch Data 

Shift, Day, Week, Month 

Feed Product and MIP 

Calculations 

Real vs Published Data 

Data Sign off and approval 

Instrumentation 

- Flows 

- Weightometers 

- Density 

•LIMS 

•Weighbridge 

•Batch Systems 

•Material Tracking 

MII 

Implementation of 

business Logic 


7 


Registered Users 

• 200 Registered Users 30-40 active users 

508 

Shades of MOM| ©2015, MESA International 

8 


Was Metals Accounting Successful? 

For sure….But!!! 


9 


#ItsAlone 

#Ping AnyOne 

• Production Requires 

• Process Reporting 

• Production Reporting 

• Weighbridge Movements 

• Delays 

• Charting 

• Material Tracking 

• Logsheets 

• Metals Accounting 

• Trending 

• … 

This is not my system it is for somebody else 


10 


Framework Core 

MES Framework 

ecWIN 

Integration 

Engine 

Datapoint 

Manager 

Data 

Collection 

Engine 

Event 

System 

Time Period 

Scheduler 

Databroker 

Aggregation 

Engine 

Calculation 

Engine 

Entity Relationship Model 


11 


Hardware Platform 

• Virtual Servers (Hyper-V Server 2012 R2) 

• Internal 

– Application server 

– Database server 

– Web server 

• 3 rd Party 

– LIMS Sever 

– Mincom Server 

– MII Server 


12 


Integration 

Locally Stored 

DataBroker 


DataBroker 


Virtual 

DataBroker 

IOT 

DataBroker 


13 


Modules 

… 

Tanker 

Plan 

LOS 

Balancing 

Block 

OPM 

OMS 

LIMS 

RockIT 

Loop 

Monitoring 

OEE 

Processing 


14 


LOS 

1. Need for a clear “line of sight” from the highest to lowest level in 

company focusing on: 

• Safety; 

• People; 

• Production and 

• Cost 

2. Line of sight Project were designed to: 

• Integrate current systems and processes which are imbedded within 

Lonmin (MineRP, SACO, Planning) 

• Tool for production gangs to manage and control performance 

• Inform line management with real time data regarding daily 

performance, actions taken and assistance required through automated 

escalation. 


15 


LOS – The Difference 

1. No Real time Data from Devices and PLC’s 

2. Nothing to do with S95 (Sites, Enterprises, PU, Units and 

Cells) 

3. No Manufacturing 

300 

20,000 

Time: 

20 mMonths 


16 


LIMS Reporting 

• Real Time Reporting 

• Have visibility of LAB results across business 

Marikana Operations 3500 

120 

Brakpan Operations 4300 

10,000 

Time: 

2 mMonths 


17 


Metals Accounting 

• Single version of the truth 

• Sustainability 

• Speed 

47 

1500 

Time: 

9 Months 


18 


Processing Module 

• Logsheets 

• Checklists 

• Charting 

380 

32000 

Time: 

As Required 


19 


RockIT 

• Capture inspection results 

• Generate an initial risk classification based on results captured. 

• Integrate with Line of Sight for better inspection planning. 

• DMR Requirement 

• Benefits: 

– Improved reporting turn-around time. 

– Improved accuracy. 

– Designed with various validation and checks 

– Improved inspection planning. 

– Accountability for inspections. 

20 

850 

Time: 

6 mMonths 


20 


OEE 

• Align with industry 

• Manage performance of plant 

• Part of Bonus Incentive 

80 

1500 

Time: 

1 mMonths 


21 


OPM Automation 

• By doing the Automation as an Internal Team an estimated 

saving based on previous experience is calculated between 

R20m-R30m 

• A combined effort between Processing technology and 

Automation, enabled Lonmin to implement a process which 

resulted in an overall efficiency increase of more than 10% on 

one of the precious metals products which translates to a once 

off cost saving of R300m 


22 


OPM Automation 

• Difference 

– Full Automation, PLC, SCADA and MES 

– Batch System 

– Logsheets 

– Reporting • Batch 

• Aggregate 

• Calculate 

100 

2500 

200 

Time: 

8 Months 

150 

100 

50 


23 

0 


Loop Monitoring 


24 


Chemical Forecasting 

Chemical Forecasting supports the business to 

simply the planning process with regards to 

Variable costing at the PMR. 

• Benefits 

– Finance team has the ability to run What-If scenarios 

and find optimized solutions for different production 

scenarios 


25 


Bulk Chemical Costing 

Provides a model used by the PMR that enables 

them to draw a line between the variable cost 

and fixed cost per plant or process. 

• Benefits 

– PMR is a chemistry plant thus this functionality 

allows them to plan, forecast accurately and 

enable them to determine the efficiencies in their 

variable consumptions. 


26 


Planned Maintenance 

• The strategy from the Engineering 

Maintenance department is to move from a 

fixed term to a utilization or condition based 

maintenance module. 

– Notification 

– Measurements 


27 


Weighbridges 

• 5 Weighbridges 

• Configuration centralised 

• Ability to run offline 

• Automatic sync of master data 

• Automatic sync between weighbridges 

• Automatic sync of data 

• Fully Integrated to framework 


28 


Event System 

Tanker Model 

Smelter Tanker Plan 

Assist with improved pre-blending of the 

concentrate to the furnaces. 

– The % of Cu+Ni in the concentrate 

– The % of Sulphur in the concentrate 

Weighbridges 

LIMS 


29 


Balancing Block 

• Metals Accounting 

• Water Balance 

• Energy Balance 


30 


Client Side Architecture 

Modules 

Balance Block 

Assay Data 

Calculation 1 

Calculation 2 

Mass Data 

Calculation 3 

Energy Data 

31 


31 


System Acceptance 

1000 

900 

800 

700 

600 

500 

400 

300 

200 

100 

0 

RockEngineeringModule 

WeighbridgeAdministration 


MSTPC 

LIMS Reporting Module 

70000 

60000 

50000 

40000 

30000 

20000 

10000 

RockEngineeringModule 

WeighbridgeAdministration 


MSTPC 

LIMS Reporting Module 

0 


32 


System Statistics 

• 600 Gig Database 

• 380,000 Entities 

• 27,000 Datapoints 

• 3,000 Calculated Datapoints 

• 8,300 Relationships 

• ~750,000 events per day 

• 4-6 Developers 

• 2 System Administrators 

• Standby < 3 calls per month 


33 


#ImAlone 

#PingAnyOne 

#PingReply 

OEE 

#PingReply 

Mat Tracking 

#PingReply 

LOS 

#PingReply 

Lims Report 

Metal 

Accounting 

#PingReply 

RockIT 

#PingReply 

Charting 

#PingReply 

Forecasting 

#PingReply 

Tanker Plan 

#PingReply 

Loop Mon 

#PingReply 

Planning 

#PingReply 

Proc Data 

#PingReply 

Logsheets 


34 


Lonmin Roadmap 

Mobile 

Modelling 

Smart Mining 

APC 

2016 

LOT 

IOT 

ML 

Optimize 

Control 

2013 - 2015 

2011-2012 

2010 – 2011 

•KPI Calculations 

•Systems Integration 

•Reduce Complexity 

•Log-Sheets 

•OEE & Downtime 

•Production Tracking 

•Material Tracking 

•MES Framework 

•Common Tools 

•Common Building Blocks 

Standardize 

& 

Cross Plant Rollout 

Rollout Base 

Functionality 

Create Platform 


35 


Conclusion 

• Started for a Need Metals Accounting 

• Build a solid Foundation 

• Rolled out functionality as requested by 

business 

• Touching a huge user base 

• Have a solid Base for Smart Manufacturing 

• Will Lonmin continue In-house Development 

– ?? 


36 


Q & A 

Gawie Reyneke 

gawie.reyneke@lonmin.com 


37 


To Improve Your Success… 

www.mesa-africa.org 


38

Gawie Reyneke MESA Africa Conference Presentations 2016 - 16 Nov

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