Cohen Egaf7

Asset Management in Mines
Key for Operational Excellence Success

Presenter: Marcelo Cohen W.
U.C Chile Structural Civil Engineer

Anglo American Chile
VP.OP.Excellence

Santiago, November 2009

VII Encuentro en Gestión de Activos Físicos Centro Internacional de Ciencia y
Campus San Joaquín, 27 de noviembre de 2009 Tecnología para la Minería
Pontificia Universidad Católica
www.egaf.cl de Chile

Anglo American in Chile

• Operates in Chile since 1980
Collahuasi
• Third largest mining company in the Mantos
Blancos
country: production is 650,000 tons of fine Mantoverde
copper a year.
El Soldado
Chagres Santiago
• Owns and operates 5 Divisions: Los Los Bronces
Bronces, Mantos Blancos, Mantoverde, El
Soldado and Chagres Smelter.

• 44% ownership of Compañía Minera Doña
Inés de Collahuasi.


Anglo American Chile Operations

Los Bronces Mantos Blancos El Soldado
Production: 236m t fine copper Production: 88m t fine copper Production: 50m t fine copper
2,5m t molybdenum Employees: 1.300 Employees: 1.400
Employees: 1.700

Mantoverde Chagres Collahuasi (44%)
Production: 63m t fine copper Production: 204m t fine copper
Production: 146m t anodes
Employees: 800 1,1 m t molybdenum
493m t Sulphuric Acid
Employees: 2.000 (100%)
Employees: 500


Operational Excellence Project

Focus in
Excellence

Best Practices
Transference CI…in practice


Excellence and Innovation Cycle

INNOVATE,
INVEST IN
OPERATIONAL
CAPACITIES
PERFORMANCE

ACHIEVE SUSTAINE
OPERATIONAL OPERATIONAL
EXCELLENCE EXCELLENCE

CURRENT
SITUATION

TIME

ROADMAP

Easy Ease versus return on investment

High ROI Easy
Low ROI Easy

MINE OPERATIONAL SYSTEMS
PLANT OPERATIONAL SYSTEMS ASSET MANAGEMENT

High ROI Hard

OPERATIONAL EXCELLENCE
• ASSET OPTIMISATION
Low ROI Hard
• ENTEPRISE COLLABORATION
• CENTRES OF EXCELLENCE
• AUTOMATION

Benefits


Asset Management


Asset Management

Asset Management?
• Asset Management is simply the optimum way of managing assets to achieve a desired
and sustainable outcome. NORM PAS 55-1
• Asset Performance Management relates to the optimal operation of a physical asset or
process to deliver maximum benefits at minimum costs.
• Intelligent/Asset performance Management (IAPM) employs advanced systems and
technologies k.o. help automate and support the APM process:
• Use of real time monitoring of KPIS.
• Real time root cause analysis
• Collaboartion / Integration / Automation
• Real time notification of appropiate personnel


Asset Management Structure

• Asset Management Framework

• Maturity Level

• Best Practices And Kpi’s Per Each Maturity level

• Setting Targets

• Assessments / Audits

• Action Plans/ Prioritization

• Monitoring


Asset Management Framework

• Strategy Management
• Safety, health, environment, risk and quality
• Organisation and Manpower
• Operational approach
• Operator Asset care
• Maintenance tactics
• Condition Monitoring
• Work Management
• Facilities, Tools and Workshops
• Shutdowns & Project Maintenance
• Information Management
• Supply Chain Management
• Cost Management
• Contractor Management
• Performance Management
• Continuous improvement and Asset
Optimisation
• Asset Life cycle Management
• Energy management


Maintenance Approach – Pillar Ops05
01
Maintenance Approach Strategy

02 04 05 06 07 09 11
Equipment Criticality Failure Mode Tactic Task EMP Training
Register Analysis Analysis Selection Development

03
Functional
Analysis Maintenance Failure Modes Decision Resources In Ellipse
Production Tree Tools
Safety Spares
Specifications Environment Root Causes Safety
Performance Regulatory 10
Functions and 08 Long-term
Probability Failure Behavior APL’s Plan
Predictive Proactive
Goals: Goals:
Develop application specific tasks per equipment through a RCM-based Develop application specific tasks per equipment and component through full
process. RCM-based process with support from OEM’s.
Tactics: KPI’s: Tactics: KPI’s:
Production unit and equipment criticality OEE per production unit Equipment and component criticality OEE per production unit, drill

Consequence Feedback Loop
EMP sheet per equipment MTBF per production unit Equipment and component failure analysis down to equipment level
Bi-annual review of tasks MTTR per equipment EMP sheet per equipment and component MTBF per equipment
Review as triggered by RCA (level 2+) Planned v Unplanned Tasks Annual review of tasks MTTR per equipment
Performance tracking per production unit RCA triggered/completed Review as triggered by RCA (level 2+) Planned v Unplanned tasks
Performance tracking per equipment

RCA
Expected Approach Profile: Tools: Expected Approach Profile: Tools:
RCM-based and RCA processes RCM-based and RCA processes
EMP sheet EMP sheet
APL’s contain:
APL’s contain: Mandatory, optional spares

Failure History
Consequences

Mandatory, optional spares Pre-inspected identified spares

To Work
Special tools Special tools and other resources
Inventory Management Policy: Inventory Management Policy:
Criticality B Criticality A

Reactive Preventive
Goals:
Adopt OEM generic task recommendations per equipment and review/improve
through triggered RCA.
Tactics:
Production unit and equipment criticality
KPI’s:
Availability per production unit
Goals:
Develop tasks per equipment type through a RCM-based process.

Tactics:
Production unit and equipment criticality
KPI’s:
Availability per production unit
Spares Usage Planning and
Control
OEM generic specifications and MTBF per production unit EMP per equipment Performance rate per production
equipment type tasks Review as triggered by RCA (level 1+) unit
Performance tracking per production unit Performance tracking per production unit MTBF per production unit
MTTR per production unit
Expected Approach Profile: Tools: Expected Approach Profile: Tools:
RCA Process RCM-based and RCA processes

APL’s contain: APL’s contain:
Mandatory spares Mandatory, optional spares

Inventory Management Policy: Inventory Management Policy:
Criticality C Criticality B

Probability of Failure


Maintenance Work Planning and Control – Pillar 06
Equipment Maintenance Plan
Condition Monitoring
Backlog Breakdowns

02 03 05 06 11 13
Work Work Work Allocation and Analysis Reporting
Identification Planning Scheduling Management

Work Resources Work Prioritise 12
Validation Tools Spares Prioritisation “Planned’
Planned’ RCA
Safety “Unplanned”
Unplanned”

Resource 07 Work Order
Levelling Safety Closure

Align with 08 Equipment
04
Prod Plan Quality History in
APLs and
Ellipse
Material
Reservations
Weekly Plan 09
Feedback
Feedback to
Maintenance
Approach
10
Component
Tracking

Excellence
Maturity Levels
Competence
Changes implemented –
working

Understanding
Implementing changes - plan

Awareness
Changes are required Operational AM focus

Innocenc Eng AM strategy Three‐year strategies aligned
e Ad hoc AM focus Maintenance & Prod strategies ERP – full integration
Not aware
Informal strategy Formal objectives & goals Operational integration
No AM focus Informal goals Strategic plans Common processes
Limited direction Some implementation plans ERP ‐ not integrated SC & supplier integration
No goals ERP – unfriendly Area silos Predictive
No plans Discipline silos Preventative Single operational data system
ERP – an hurdle Reactive Single area data system LCC & TCO Benchmarking
Individual silos Various data systems One version of the truth Automated data management
Firefighting Various versions of the truth Area KPIs Operational KPIs
Individual KPIs Discipline KPIs $ / Hour & Tonnes/Hour $/Tonne, OEE & EBIT
Availabilities / Tonnes $s / Hours / Utilisation Area Dashboard BU and Group dashboards
Individual reports Functional monthly reports Daily reports In‐time reports


Best Practices
Maintenance Evolution

Not only repaired,
but better!!! I VE
AC T
Detection of abnormal P RO
conditions
IVE
D I CT Achieving World
Repair Before P RE Class
Failure
Performance
Maintenance

Repair After Failure NED
PL AN Competitive
Advantage
E
T IV
R EAC No Surprises

Overtime

Firemen Planned Disciplined
10% - 15% costs Learning Organization

25% - 40% costs


Mine PdM Techniques


Plan Pdm Techniques


Condition Monitoring


Asset Optimization


Asset Optimization General Approach

Operational Value Tree Capacity Constraint System Operational
Flow Charts Design Analysis Analysis Bottleneck KVDs
Definition Definition

Benchmark GAP Prioritisation
Setting Definition
(physical)

Action Implement Monitor & Report
Plans Control


Mine Operation Flow Chart

GRIDING MILL


The value tree and Asset Management

Cycle Distance

Productivity – T/Hr Cycle Time
Prod Approach
Efficiencies
Asset Care

Revenue Tonnes Maint Tactics
Scheduled Hrs

Eng Avail % Condition
Monitoring
Unscheduled
TCO - Utilisation - Hours Prod Avail % Hrs Work
$/Tonne Management
Utilisation %
Supply Chain
Overheads Performance
Project Costs Maint Labour Mngt
Prod Labour
Maint Costs AO
Consumables
GET Asset LC Mngt
Costs - $/Hr Fuel
Lubs
Power
Other


Enabling Operational Excellence

Production, Quality, Costs, Equipment Availability, Environmental and Safety alerts with
fast resolution and improved decision making.

Continuous Improvement and Innovation
MONITOR IMPROVE

Yes Yes
KPIs Satisfied ?
In Control ?
No No

Identify Root Establish
Causes Alternative

Operations/ Mintenance Engineering/ Management


Enterprise Collaboration


Mining and Plant Control Process and System
integration
Mining Integrated Control System
• Oriented to control the mining operations locally
• Fleet management.
• Maintenance management.
• Safety management.
All operational & maintenance KPls (per equipment, per fleet) should be
calculed at this level.

Benefits Systems Integration
• One of the major benefits of the mining integration is the composition tracking
of the blast and mineral characteristics, that allows:
• Energy optimization in Crushing and Griding while maximizing the throughput.
• Separation and recovery efficiency of the metals in flotation.


Mine to Mill

Geology

Drilling and Blasting
Operation Plant

M2M

Planning process
Operation Mine


The Relevant Variables In The Mine To Mill
Process

DRILLIND
GEOLOGY
AND BLASTING

Variables: STEMMING
• Rock Type OR PRIMARY
CRUSHER Variables:
• Alteration POST BLAST Setting Primary Crusher
• Hardness
• Fracture Frequency Variables: POST CRUSHER
• Drilling Grid
• Explosive Type
• Load Factor (LF) Variables:
• Blast hole configuration • Continuity of Feed to Plant
• Blending
CM 3

GRIDING
PLANT
Smart Tag
Variables:
• Lining design Variables:
• % steel balls • Stock Pile Height
• Expert control • Tripper Strategy
GRIDING MILL FEED • Model stock behavior
•Material Segregation
C 1-1 ; C 1-2

Systems Information
Objectives

• To support Asset Management.

• Enhance Operational Excellence through:

» Asset Monitoring ( Efficient Asset Management)

» Process Control (Efficient Managemnet of the Process)

• In Real Time collaboration

• Integration of the ERP and Ancillary Systems


Intelligence
Business
LEVEL 5

Data Cubes Reports Business Objects
& – , Carbon V

Data WarehouseSQL2005
–
Extract TransformLoad- Sonic ESB
, ,

MER/BO
Enterprise Portal

ERP- Ellipse/ SAP ERP- SAP Ancillary Systems
Geology
theSource

AcQuire/
Datamine Mine
SCM Sales
Business Planning

Planning&
& Management

Finance& Inventory
&

EMC Documentum
Procurement HR & Payroll Marketplace Catalogues Management
Scheduling Costing Warehousing
LEVEL 4

Quardr m & e-
e LinkOne Aramis/ Micro
Datamine
/

DMS
hub Connect Minemarket
Survey Minesight
ESRI/ Autodesk

Budgeting
& Outbound
Operational Logistics SD/HSEC
Engineering Modeling & Maintenance Production Planning Anglo Safe
PH e
-Truck
/
Hyperion
Autodesk Optimisation MineMarket
Carbon E

Sonic ESB ETL Integration
&
Management
Operational

-
LEVEL 3

Plant Mining- Underground Mining Opencast LIMS& Assay Management T&A & Access Control ConditionMonitoring
Operational Portal

/
Fleet
MES MES Online LIMS Webcontrol
OSISoft PI OSISoft PI
OSISoft PI Management
???

Modular Jigsaw
Unit Control
LEVEL 2

Not Not Not
Prescribed Prescribed Prescribed
easurement

Levels Alarms Temp PressureAcceleration
, , , , , Weight Volume Voltage CurrentMeters Rates Parameters for Performance
, , , , , , , Consumption etc
LEVEL 1
M


Anglo American Chile – Process Operations
Management (PI System)


AM KPI´s

Los Bronce (Eng / Esp) Mantos Blancos (Eng / Esp) Mantoverde (Eng / Esp)

El Soldado (Eng / Esp) Chagres (Eng / Esp)

30

OID Dashboard - Drilling


Centres Of Excellence

Enable Capture Of Economies Of Scope To Drive Superior Operational Performance And Utilization
Of Scarce Talent

Expert(s) are able, through enhanced communications capabilities and a set of agreed upon metrics and
shared data, to detect a problem, manage a process and/or provide solutions to specific problems or
guidance to the people in a remote operation.

Equipment / Process Monitoring

Centre of MINE
Excellence

Service Activities


Automation


Máquina Despegadora Robótica


Cohen Egaf7

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