Operational Excellence for the Mining Industry •
Track material through your value chain
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Reduce costs and improve operating margins
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Improve asset availability, utilisation and effectiveness
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Ensure safety and regulatory compliance
Operational Excellence For the mining industry Matrikon allows you to achieve Operational Excellence through the continuous improvement of operational processes that are in alignment with corporate objectives.
Built on industry standards and vendor independency, Matrikon™ Mining Solutions integrate with your existing software and legacy equipment to unlock the power and potential of your people, your mine and your process.
The Operational Excellence Challenge In today’s competitive global environment, where commodity prices fluctuate, equipment costs remain high and expertise is diminishing, organisations are required to extract more value from their mining assets and processes. Matrikon Mining Solutions lead to substantial improvements in production, quality, safety, environmental compliance and profitability.
Achieve Operational Excellence The Mining industry’s information requirements fall into two key areas. At the operational level, the industry needs reliable control and performance monitoring, accurate information on equipment condition, accurate reporting, and easy access to all operational data. At the business level, the Mining industry needs to track various products as they move through the supply chain, to manage assets effectively, to plan and schedule for future activities, and to have access to reliable performance indicators. Years of process industry expertise coupled with best-of-breed technology have cumulated with a Mining Solution that addresses and resolves industry needs and ultimately meets the objective of achieving Operational Excellence.
Operational Excellence for Mining
The Operational Excellence Process Asset Effectiveness Multiple mining assets throughout various locations must run reliably and at highest capacity, optimised against maintenance costs.
Operations Optimization In order to have control systems operate at maximum efficiency and performance, operators require powerful tools to better manage the process.
Rotary Breaker
Apron Feeder Sizer Oil sand from the Mine
Feed Conveyor
HPW Oversize bin Breaker Pumpbox
Production Management Organisations require the ability to continually manage material as it moves through the mining operation. Easily compare planned vs. actual and raw vs. reconciled production.
Informed Decision Making Decision makers throughout an organisation require accurate, auditable and meaningful data in order to make informed decisions.
Matrikon Solutions throughout the Mining Operation ERP Systems: Accounting, Payroll, HR, Maintenance, Document Management
Enterprise-wide Data Warehousing: KPI’s, Production, Dashboards, Planning, Decision Support
Scheduling, Survey, Reconciliation
Planning, Quality, Production, Consumables
Campaigns, Downtime, Stockpiles, Quality
Orders, Scheduling, Logistics, Inventory
Mine Planning & Design
Mining Operations
Beneficiation and Minerals Processing
Distribution & Transport
Mine Design & Modeling
Data Historians
Data Historians
Transport (Trains, Trucks, Conveyors)
Wired & Wireless Communications
Advanced Control & Expert Systems
Fleet Management & Dispatch Systems
Process Control (PLC, SCADA, DCS)
Environmental Systems OEM Systems
Instrumentation & Drives
Geological Modeling and Feasibility
Exploration
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Ports & Loading Terminals
Customer
Innovative solutions for Mining leaders • •
Planning, Logistics and Execution management within an integrated applications environment with delivery of information in real-time Deliver the right information to the right people at the right time to improve decision making
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Applications that support streamlined business processes
Matrikon™ Mobile Equipment Monitor Remotely monitor equipment and operator performance in real-time. • • •
Monitor any mining equipment, regardless of vendor Predict and prevent incidents and failures Significantly extend equipment life and reduce downtime
Analyze and improve fleet and operator performance in real-time from a single location. Matrikon Mobile Equipment Monitor enables access to remote operating data for the immediate visibility and analysis of equipment and operator performance. It is a comprehensive and scalable monitoring system that meets the requirements of the smallest mine or the multiple-site enterprise. Matrikon Mobile Equipment Monitor collects all available operating data from the equipment’s onboard sensors and systems and transmits it over the mine operator’s network to a central database. The data is immediately available for real-time visualisation and analysis.
Matrikon™ Mine to Port Gain full visibility of your supply chain in real-time. • • •
Monitor progress, modify plans and deal with problems quickly Increase availability and improve utilisation of mine assets Eliminate data silos with a web-based solution
Companies that mine, process, stockpile and sell bulk materials, base and precious metals need real-time visibility into their supply chain. Capture the knowledge of your operation and act in a predictive manner rather than reactive. Matrikon Mine to Port integrates and presents data from all operational systems regardless of vendor to transform data into operational intelligence. Unlike applications that focus on specific functional areas, Matrikon Mine to Port is an enterprise solution that includes components for the entire mining operation, including Ore Source Management, Material Tracking, Planning & Scheduling, Inventory Management, Reconciliation, Rail Operations, and Marine/Port Operations.
Operational Excellence for Mining
Improve Asset Reliability, Optimise Process Performance, Better Manage Production Matrikon™ Suite bridges the gap between instrumentation and business systems to enable and sustain Mining
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“Matrikon Mining Solutions deliver information instead of mere data. Data is easily understood thanks to comprehensive graphing functions. At the touch of a button I can instantly gauge the performance of the plant and manage the production and maintenance accordingly.”
Shaun Booth Plant Manager Bulga Coal CPP, Xstrata
www.matrikon.com
Matrikon’s Asset Effectiveness and Operations Optimisation products provide condition monitoring, alarm management and operational insight, while our integrated Production Management suite provides a Mining operation with an information system aggregating data from all operational layers, ensuring consistency, clarity, and a single version of the truth for everyone. Asset Effectiveness Monitor, maintain and enhance mining equipment reliability in order to achieve and sustain optimal availability and utilisation of assets.
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Operational Excellence by better managing existing data.
Matrikon Suite for the Mining Industry
Operations Optimisation Simulate, optimise and safeguard Mining assets for improved performance through alarm management, enhanced process control and visualisation. Production Management Manage and consolidate disparate data into one auditable, consolidated Mining Information/ Supply Chain solution.
Matrikon Suite Solutions are supported by: Universal Visualisation Matrikon™ Operational Insight is a thin-client application that provides data integration, information and visualisation from existing control systems, real time historians and relational data sources. Plant and Process Centric Data Model Consists of a Registry, Data Dictionary and Object Meta Model that couples the real-time world with the business world. Universal Connectivity OPC is the published industry standard for integrating the control layer with the information / application layer. OPC drivers provide connectivity to all common PLC, SCADA, DCS and Historian systems.
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Monitor, enhance and maintain the performance of your critical mining assets. Predict failures and disruptions, plan and achieve optimised maintenance, and ensure the availability and integrity of all assets and processes. • • • •
Increase revenue Decrease maintenance costs Reduce equipment damage Ensure industry and government compliance
Achieve Operational Excellence through Asset Effectiveness Challenges Successful operations are dependent on the performance and continual availability of plant assets. The data systems that control and monitor these assets are inherently vulnerable. Assets and performance must be monitored, maintenance must be effectively scheduled and processes must be secured.
Objectives Improve performance and quality, reduce costs, increase production efficiency and achieve higher return on assets by predicting failures and disruptions before they occur, planning and achieving optimised maintenance, and ensuring the availability, integrity and sustainability of your process.
Solutions • • • • •
Equipment condition monitoring Integration for work management, reliability, and condition monitoring Maintenance and reliability program development assessments Work management system implementations and work practice development Network security assessments and compliance services
Industry expertise and an in-depth understanding of asset operating challenges allows Matrikon to help clients assess their current performance against best practices, and maintenance and reliability programs empowers mining organisations to move to a condition-based maintenance environment.
“Matrikon has created software that gives me usable information instead of mere data. Information presented is easily understood thanks to the comprehensive graphing functions and at the touch of a button I can instantly gauge the performance of the plant and manage the production and maintenance accordingly”
Operational Excellence for Mining
Shaun Booth Plant Manager Bulga Coal CPP, Xstrata
(CBM) Condition-based Maintenance Predict and reduce equipment failure • • •
Reduce unscheduled downtime Identify under performing assets Optimise maintenance resources
Quantify mining equipment health and diagnose the root causes of poor asset performance. Because equipment failure is predicted before incidents and hazards occur, maintenance costs are reduced and production quality and capacity increases. Matrikon™ Equipment Condition Monitor
Quality Assurance Maintain and improve product quality • • • •
Matrikon™ Process Performance Monitor
Monitor all process units on a single screen Abnormal event detection Reduce variability Ensure environmental compliance
Identify process abnormalities before they lead to out of spec production. Drill down into specific performance issues and directly compare benchmarked local and remote operating units.
Reducing Downtime Identify missed opportunities • • •
Predict trends of systemic problems Associate costs to production downtime Access predefined reports, KPI’s and corporate strategies
Automatically collect downtime and production data from control systems in order to target root causes of costly missed opportunities and disruptions and ensure accountability and compliance. Matrikon™ Downtime Reporter
Cyber Security Management Manage a comprehensive security program • • •
Matrikon™ Network Security Manager
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Effortless compliance cyber management Develop a comprehensive security program Ensure cyber security and availability
Create a cohesive industrial security program for disparate plant systems. Improve plant cyber-security and resource availability, quantify and visualise risks, and automate workflow and report generation.
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Address the day to day activities of mining operations. Monitor and analyse the performance of control systems, manage and rationalise alarms, visualise and gain insight into processes and easily log operations.
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Ensure optimised operation with better control Reduced unplanned shutdowns and process upsets Ensure reliable alarm systems Meet industry compliance and reporting requirements
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Achieve Operational Excellence through Operations Optimisation Challenge Effective operations are dependant on vigilance and reliable process control. Hundreds, even thousands of regulatory loops and many advanced process control applications are difficult to monitor and maintain. Ineffective alarm systems often overwhelm operators rather than assist their efforts and operations become reactive rather than proactive.
Objective Improve control performance, implement a comprehensive alarm management program and gain valuable insight into your mining processes through powerful visualisation. By optimising resources such as raw materials, labor and equipment, you will maximise profits, ensure a safe environment and achieve compliance through an auditable trail.
Solutions • • • •
Alarm management Control performance monitoring Powerful, web-based visualisation Comprehensive operations logging
Matrikon Operations Optimisation provides a systematic approach to leverage existing infrastructure and data to drive on-going process performance through reduced operating costs, increased throughput and yields, and meeting environmental and regulatory requirements.
“Matrikon helped us realize over $1 million in savings during the first nine months alone; we have a sustainable, quantifiable data driven approach to improve production.” Jorg Ruppenstein Process Control Engineer Abitibi Consolidated
Operational Excellence for Mining
Alarm Management and Rationalisation Optimise alarm system performance • • •
Improve plant safety Ensure fast and thorough incident reviews Ensure EEMUA 191 and ISA SP 18.02 compliance
Collect and store all alarm and event data and automatically, generate web-based, standards-compliant KPI reports that provide an accurate snapshot of the current state of alarm management at the plant. Matrikon™ Alarm Manager
Reduce Variability Improve and sustain control performance • • •
Improve control loop and APC performance Reduce loop tuning and APC implementation costs Enable condition-based maintenance of control assets
Monitor, identify, diagnose and remedy control issues across all plant layers. Loop tuning, modeling and multivariate step testing capabilities not only improve control performance but sustain it as well. Matrikon™ Control Performance Monitor
Capture Operational Knowledge Gain insight into the state of plant operations • • •
Capture operator knowledge Ensure operating instructions are followed Enable fast and thorough incident reviews
Capture and record unit shutdown and slowdowns and status of critical equipment to ensure complete and thorough shift hand-over. Matrikon™ Operations Logbook
Real-time Web-based Data Visualisation Patented treemapping technology • • •
Access all your data, regardless of location or format Seamlessly deliver information anywhere, anytime Create and monitor enterprise KPIs for decision support
Enable better operational decisions through powerful trending, charting, monitoring, reporting and displaying capabilities. Provide the right people with the data they need, when they need it and in the correct format. Matrikon™ Operational Insight
www.matrikon.com
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Ensure consistency, clarity and a single version of the truth for everyone participating in the management of supply chain logistics.
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Continuous monitoring ensures your targets are met Manage quantities, qualities and ownerships of inventories of all materials Actively follow key performance indicators driving your business Unify production balances with expected unit yields Comply with industry information auditability standards
Achieve Operational Excellence through Production Management Challenges
Mining organisations are flooded with operational data and the ERP level is facing increasing demands on data access. Organisations must streamline the applications layer and deliver improved business process efficiencies through integration and automation.
Objectives
Improve overall operational performance by integrating workflow and decision-making processes to create a marriage between real-time systems and business systems, the key to achieving a new level of sustainable production improvement.
Solutions • • • • • •
Production Planning and Scheduling Mine Source Management Inventory Management Movement Management Train Management Shipping Management
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Reconciliation & Mass Balancing Plant Information Management Equipment Specification Data Management & Reporting ERP Integration
Matrikon Production Management aggregates data from a variety of disparate applications, facilitates calculations and analyses, and acts as a data repository when necessary for supporting applications at either the process level or at the business level. The information is available to all users within the mining operation and enables timely, accurate decision making based on real operational and business knowledge.
Operational Excellence for Mining
Comprehensive Production Planning Match production to production order • • •
Matrikon™ Plan Management
Publish long-term, monthly and daily plans and schedules Convert schedules to operating instructions Automate interfaces to ERP and financial systems
Manage long-term plans, shorter-term production schedules, shipping schedules, and schedule blending for accurate bench marching, performance evaluation and continuous online comparisons against actual production.
Inventory Management Complete visibility of material transactions • • •
Matrikon™ Materials Management
Batch Tracking with forward and backward genealogy Laboratory sample and analysis tracking Management of material quality specifications
Gain complete visibility of all material transactions, material qualities and inventories across the entire supply chain. Access validated data on quality, quantity, composition and ownership collected or derived from diverse real-time and transactional plant systems.
Balanced, Reconciled, Auditable Accounts Manage all aspects of the production accounting process • • •
Matrikon™ Production Accounting
Balance volume, mass, energy, components at any level Calculate loss quantities, qualities and ownership Easily maintain models and data sources
Use a complete set of balancing and reconciliation tools that are fully integrated with the intelligent plant model, enabling the consolidation and access of information from all plant data sources.
Compare Planned vs Actual Operation Continuously monitor complex performance indicators • • •
Enable online benchmarking Active comparison of plans versus actual operation Detection and alerting of non-conformance events
Enable real-time visibility of complex performance indicators associated with processing of materials, from receiving, through unit operations, to shipping. Matrikon™ Performance Management
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INDUSTRIAL AUTOMATION & Optimisation SERVICES Matrikon has been implementing comprehensive automation solutions to the mining industry for over 20 years. Our depth of expertise allows us to successfully meet and exceed automation requirements for electrical, instrumentation and control.
Scoping Studies/Preliminary Engineering
Our automation and control design, implementation, commissioning and support experience allows us to deliver comprehensive and workable scoping studies and preliminary engineering for our mining clients.
Standards Development
Development and provision of standards for documentation (e.g. functional specifications), DCS and PLC programming, HMI and SCADA development, communication networks and technology (including OPC), electrical and instrumentation systems and alarm management.
Vendor Independence
Matrikon has worked with virtually every major automation, instrumentation and electrical system vendor including companies such as ABB, Siemens, GE, Schneider Electric, Honeywell, Ivensys, Rockwell, and Yokogawa.
Plant Optimization
Services include control loop design, tuning & optimization, control performance monitoring, alarm system performance analysis and improvement, advanced data analysis and dynamic process control simulation and testing.
Safety Systems
Certified functional safety engineers and instrument & control system engineers will review your safety systems including design documentation, safety systems (AS61508 & AS61511) design and implementation, machinery safeguarding (AS4024) and the coordination and execution of CHAZOP studies.
Train Loading
Matrikon has been extensively involved in the automation of train loading systems for over 13 years. Our experience extends to batch, volumetric and mass loading system automation. Matrikon also has considerable experience in Train Speed Indication (TSI) Systems design and implementation.
“Matrikon is the most client-centric company I’ve ever had the privilege to do business with.” Donald Campbell Brown Team Leader for Facilities Excellence BP
Operational Excellence for Mining
The Matrikon Advantage
Leading Technology
Professional Services
Customer Partnership
Leading Technology
Professional Services
Customer Partnership
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Serving over 65% of Fortune’s Global 500
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Complete service provider, from planning to execution
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100% focus on customer success
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19 offices & 12 partner companies around the world
Unified architecture enables scaling from single site or department to entire enterprise
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Over 80 corporate license agreements
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Modular solutions target greatest needs
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Regular conference & client showcase
Largest independent integrator in North America •
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Over 5,000 installations of Matrikon Suite products
Vendor independency allows for easy integration e easily with existing IT investments
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Over 100,000 MatrikonOPC installations
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Quick ROI: 3 to 6 months
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MTK experts sit on industry committees like OPC, NERC, ISA…
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Recognized leader: #43 on Control Top 50
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Successful Execution Deployment Matrikon follows an execution strategy that combines the necessary risk management with breakthrough technology coupled with process change management procedures to prepare the business to adopt the business processes, as well as the conventional project management.
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Deliver Baseline Design Model Build Integrate Transform Accept
Realize Tune Embrace Service Verify
Prosper Evaluate Extend Evolve Advance
Client Experiences Rio Tinto Improves Coal Yield and Reduces Costs About Rio Tinto Rio Tinto is a world leader in discovering, mining and processing the earth’s mineral resources. The Group’s global operations supply essential minerals and metals that help to meet global needs and contribute to improvements in living standards. Challenge Achieve higher throughput and reducing production variability while minimising costs and production loss. Solution Matrikon Mining Solutions identified key improvement opportunities, upgraded the control system and implemented advanced control strategies on legacy systems. Successes Rio Tinto Coal Australia Hunter Valley Operations together with Matrikon won the “Minerals Process Plant of the Year” Award at the Australian Mining Prospect Awards for Innovation in Coal Prep Plant Control Optimisation.
Operational Excellence for Mining
“Matrikon Solutions allowed us to report on our multiple plant operations throughout the enterprise and enables high level information management with drill-down capabilities. System changes and support can be remotely performed with Matrikon’s efficient and effective service.” Luke Dimech Superintendent Planning and Improvements Hunter Valley Operations, Rio Tinto Coal Australia
Delivering Operational Excellence around the World
Matrikon Mining Solutions are found in use by some of the largest companies in the world including:
Coal Rio Tinto BHP Billiton AngloCoal Thiess Xstrata Coal Roche Henry Walker Eltin BHP Billiton Mitsubishi Alliance Excel Unimin Roche, Thiess, Linfox Centennial White Mining Bloomfield Queensland Rail Port Waratah Coal Services Pacific National Dalrymple Bay Coal Terminal (DBCT) Chain Valley Colliery (Private) Whitehaven Wesfarmers Curragh Sherrit International Central Queensland Ports Authority
www.matrikon.com
Oil Sands Syncrude Suncor Mineral Sands Iluka Resources Iron Ore Rio Tinto BHP Billiton Comvex Bulk Materials Handling (Romania) Steel Smorgons BHP Steel Onesteel Bluescope Steel Silver BHP Billiton Nickel BHP Billiton Phelps Dodge Inco Lead/Zinc Zinifex (formerly Pasminco)
Gold/Copper Newcrest Mining Rio Tinto Xstrata BHP Billiton Sterlite Copper Barrick Gold Goldfields Ltd Kalgoorlie Consolidated Gold Mining Newmont Mining Kennecott Utah Copper Lihir Gold BEMA Gold Falconbridge Placer Dome Uranium BHP Billiton Rio Tinto Alumina Rio Tinto Alcan Queensland Alumina BHP Billiton
Aluminium Tomago Aluminium Alcan Hydro Aluminium Noranda Magnetite Unimin Phosphate Southern Cross Fertilisers Incitec Explosives ORICA Dyno Noble Queensland Nitrates Cement Blue Circle Southern Boral Lafarge CEMEX Specialist Minerals S & B Industrial Minerals
Matrikon EMEA 1 Rubislaw Terrace Aberdeen, United Kingdom AB10 1XE
Americas
Asia-Pacific
EMEA
Edmonton, Alberta
Newcastle, New South Wales
Aberdeen, Scotland
Calgary, Alberta
Brisbane, Queensland
Kﾃ僕n, Germany
Vancouver, British Columbia
Gladstone, Queensland
Matlock, United Kingdom
Toronto, Ontario
Townsville, Queensland
Al Hidd, Bahrain
Cleveland, Ohio
Perth, Western Australia
Houston, Texas
Singapore
Phone: 1-780-448-1010 Fax: 1-780-448-9191
Phone: +61 (2) 4960-1000 Fax: +61 (2) 4960-1212
info@matrikon.com Printed in Australia
w w w.matrikon.com Operational Excellence for Mining
Phone: +49 (221) 969-77-0 fax: +49 (221) 969-77-22