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Digital Mining Enterprise (DME):
Integrated Application Landscape using SAP Solutions
Nikhil Chaturvedi
IBU-Mill Products & Mining, SAP Asia Pte. Ltd.
© 2012 SAP AG. All rights reserved. 2
Disclaimer
Please note that, in this document, some of the predictions about mining
industry related processes and technology are based upon our current
understanding and foresight. Also, as the predictions relate to a mining
enterprise of future, the long time-span makes visibility and predictability
rather uncertain.
The predictions and future visualization in this document should be treated as
indicative.
© 2012 SAP AG. All rights reserved. 3
Agenda
Digital Mining Enterprise (DME)
Characteristics
Objectives
Dimensions
DME: Application Dimension
Enablement through SAP Manufacturing Integration and Intelligence (MII)
DME: Infrastructure and Connectivity Dimension
CISCO-SAP Collaboration for DME
Prioritized Work Areas
– Remote Operations Centers (ROCs)
– Expert-on-Demand
– Incident Management and Safety
© 2012 SAP AG. All rights reserved. 4
Digital Mining Enterprise (DME): Sneak Preview
Mining operations to be controlled from Remote Operations Center (ROC)
Intelligent equipment have been making decisions based on the real-time
working conditions
Greater involvement of Field Robotics and Autonomous Haulage Systems
© 2012 SAP AG. All rights reserved. 5
Where a particular data gets entered into the “application landscape” of that
mining company only once and…
… is accessible across various other applications and to different people, depending upon:
– Data mapping rules
– Workflow rules
– System authorizations etc.
… is capable of being accessible across various kind of devices like:
– Desktops and laptops
– Tablets
– Mobile phones
– Smartphones
– Handheld devices
– Scanners
– RFID devices etc.
– and any others that may emerge over a period of time
Digital Mining Enterprise (DME): Characteristics
© 2012 SAP AG. All rights reserved. 6
Digital Mining Enterprise (DME): Characteristics (Contd.)
Where the mining organization has
the capability of orchestrating
information systems on-premise
and on-demand with ease and
confidence
Where the system has adequate
flexibility, scalability, security and
interoperability to provide access to
the company data or information to
not only employees, but also
external stakeholders like
customers, suppliers, partners,
regulatory agencies and public at
large - - depending upon the
access authorizations for each
person in specific
© 2012 SAP AG. All rights reserved. 7
Digital Mining Enterprise (DME): Characteristics (Contd.)
Where integration and intelligence are available end-to-end across
various functional areas like:
Mine planning, scheduling and operations
Processing operations: Planning and Execution
Equipment maintenance
Environment Health and Safety (EH&S)
Operational Reporting & Intelligence
Energy Management
Contract-to-Cash
Transportation & Logistics
Procure-to-Pay
Project Management
Financial & Cost Accounting
Human Resources etc.
Focus of today’s
presentation
© 2012 SAP AG. All rights reserved. 8
Digital Mining Enterprise (DME): Objectives
Enhancing Delivered Throughput (Production + Processing + Transportation)
Greater operational efficiency and productivity (taking into account the constraints like
declining grades, inadequate skilled people availability, difficult terrains, greater depths,
higher rock stress, impact on environment)
Reduce the operational costs in Mines and Processing Plants
Reduce the combined Total Cost of Ownership (TCO) of various applications running in
the Mining, beneficiation, processing and transportation areas
Improve collaboration among various functions
Reacting real-time to geological conditions using intelligent and remote-controlled surface
mining equipment AND underground mining equipment
Increase exploration efficiency using Intelligent drilling rigs and improve the quantity and
quality of data acquired from borehole
Have you prioritized the key drivers for your mining organization?
© 2012 SAP AG. All rights reserved. 9
Digital Mining Enterprise (DME): Objectives (Contd.)
Convert the current sub-economic resources to profitable reserves (esp. deep hard-rock
metal resources; near surface radioactive & beach minerals etc. that can not be mined using
current technology)
Increase Overall Equipment Efficiency (OEE) based on Availability, Utilization, Efficiency,
Quality
Creating visibility into the operational and maintenance data
Increase Supply Chain & Logistics Efficiency and Inventory Visibility
Improve safety and environmental compliance
Increase Human Capital efficiency and productivity by freeing up Mining manpower for
more analytical and value-adding roles rather than regular mundane jobs
Providing better working conditions to the Mining employees, often in “Remote Operations
Centers” away from the Mining and processing plant shop-floor, that in turn will help in
attracting and retaining the workforce
Have you prioritized the key drivers for your mining organization?
© 2012 SAP AG. All rights reserved. 10
Connectivity and Infrastructure (esp. in Remote Mine Sites)
Data | Voice | Video
Mesh networks
Industrial Ethernet (Wired) and Wireless
IT Applications (Enterprise apps, Mobile apps)
Usability
Integration
Collaboration
Online and Offline functioning
Operational Technology (OT) and Automation
Mining (including Remote Operations Centers – ROCs, GPS, GIS etc.)
Processing plants
Integration of IT and OT
(Big) Data Management
Rugged Mobile and Handheld Devices
Information Access and Security
Digital Mining Enterprise (DME): How to Achieve it?
Key Dimensions
Digital Mining Enterprise:
Application Dimension
© 2012 SAP AG. All rights reserved. 12
Enterprise
Management
System
Production
Control
Systems
Mining
Specialist
Systems
Integrated
Systems of a DME
Geological
Modelling
Reserve Est.
Mine Design
Mine Planning
Mine Scheduling
Automation
PLC/DCS
SCADA
Data Historian
Plant Execution Systems
Finance & Costing
Human Resources
Materials Management
Plant Maintenance
Investment Management
Logistics Management
Workflow
Quality Management
Environmental, Health & & Safety
Knowledge Management
Business Planning & Consolidation
RFID
Vehicle Dispatch System (incl.
GPS)
Business Intelligence, Dashboards
Mobile Solutions
Business-to-Mining Integration
Weighbridge systems
GIS
Loading systems
Stockpile management and
blending
Mining System Landscape: Myriad of Applications
© 2012 SAP AG. All rights reserved. 13
SAP Solutions for integrated mining supply chain
(Pit-to-Port)
Sales & Shipping
Transport Processing Mining
Production Stockpile Stockpile Stockpile
MES
Real time
18 months
Month/week
Daily
Daily & Shift
Execution
20 years Long Term
Planning (Life of Mine)
Medium Term
Mine Planning
Short Term
Detailed
Mine Scheduling
Sales Forecasting
Integrated Supply Chain Planning
Short Term Processing
Scheduling
Rail & Shipping Scheduling
Rail & Shipping Execution
Short Term Mine
Schedule
Maintenance
Production
Inventory
Costing
Quality Sales &
Invoicing
Stockpiling
Quality
Connectivity & Real-time Visibility: MII, Netweaver PI
Commodity Pricing
Fleet Mgmt. Historian MES
SAP Best Practices for Mining delivers preconfigured scenarios for most areas of the supply chain
SAP ERP /
Business Suite
Partner Products
SAP ERP +
IS-Mining
Maintenance
Production
Inventory
Costing
Quality
Electronic Weighbridges
© 2012 SAP AG. All rights reserved. 14
Integrated Landscape of a Digital Mining Enterprise:
Using SAP Manufacturing Integration & Intelligence (MII)
Production
Planning
Production
Reporting
Maintenance
Management
Environmental
Health & Safety
Quality
Management GLOBAL
COORDINATION
LOCAL
EXECUTION
HQ-to-Mine /
HQ-to-Plant
INTEGRATION
Integration
Enable a
Single Version
of the Truth,
synchronized
operations
Intelligence Empower mine
personnel and
enable real-
time decision
making
Innovation
Deploy new
mining &
beneficiation
processes and
composite apps
Manufacturing Composite Application Services
Process
Automation
Systems
Fleet Management
System (VMS)
Mine Planning &
Scheduling
VIP (Partner Solution)
SAP MII
SAP ERP, SCM, EAM, EHSM D
IGIT
AL
MIN
E
Other Partner Solutions Weigh Bridges
DIG
ITA
L M
INE
© 2012 SAP AG. All rights reserved. 15
Enterprise SAP NETWEAVER
Oth
er
SA
P B
us. S
olu
tio
ns
S
AP
B
/ B
OB
JI
SAP Manufacturing
(SAP ERP)
Manufacturing Intelligence Dashboards
SAP MII
Manufacturing Integration
Manufacturing Intelligence
Manufacturing Integration
PI
• Production Confirmations
• Process Messages
• Material Receipts
• Material Consumptions
• Material transfers
• Inspection results recording
• Quality Notifications
• Batch Characteristic recording
• Work Orders & results
recording
• Maintenance Notifications
SAP MII’s ability to
perform transaction
execution into SAP also
enables automated,
plant-level creation of:
• Planned Orders
• Bills of Material
• Production & Process Orders
• Material Inventory Levels
• Inspection Lots Data
• Master Recipes
• Material Details
• Batch Details
• Resources & Functional
Locations
• Maintenance Work Order &
Notification details
• Material & Order Costs
SAP MII extracts data
from SAP ERP and
provides real-time
visibility and distribution
to Mine / Plant Systems
SAP MII synchronizes Mining & Processing Operations
with the Enterprise, in heterogeneous IT landscapes
© 2012 SAP AG. All rights reserved. 16
SAP MII: Services Based Architecture
Data Services
Real-time integration of data with plant floor systems, applications and legacy systems.
Visualization Services
Extensible presentation layer presented via web pages. Family of configurable UI
objects provide manufacturing views in role based dashboards or via wireless PDAs.
Business Logic Services
Flow based logic engine, enables data aggregation and transformation of disparate
data. Transactions can be triggered or scheduled. KPI Calculations, business rules,
and alerts are easily developed and executed.
SAP MII Data Services
Visualization
Services Analytic Services
SAP MII is a service-based composition environment that leverages unique services for rapid development of Manufacturing Integration and
Intelligence applications across all industries served.
Business Logic
Services
Web Services
© 2012 SAP AG. All rights reserved. 17
Digital Mining Enterprise:
Operational Visibility and Control using SAP MII
The real-time visibility of what happens on the shop floor and the
possibility of all those involved in the manufacturing and delivery
process working together is essential to improve processes, reduce
costs and intermediate stock levels and moreover the improvement
in various industry operational indicators.
© 2012 SAP AG. All rights reserved. 18
Digital Mining Enterprise:
Operational Reporting and Dashboards using SAP MII
Increased Visibility into to operations and improve decision support
$4-12MM annual (sustainable) savings on energy use per plant
© 2012 SAP AG. All rights reserved. 19
Digital Mining Enterprise:
Analytics for Mining and Processing using SAP MII
Manufacturing Analytics (for Mining & Processing)
• Complete SPC analysis suite delivers actionable real time variable and attribute
analysis
• Trending functions enable relation of process analytics to orders, lots or batches
• Drill down functionality empowers users to quickly execute root-cause analysis
© 2012 SAP AG. All rights reserved. 20
Digital Mining Enterprise:
Work Process Management using SAP MII
Work Process UI
• Facilitates integrated, automated, safe and compliant execution of all work
process steps along execution.
• Out of the box templates for easy adjustments and maximum adaptation
• Built in integration to SAP Business Suite avoids data duplication and provides
lowest TCO
© 2012 SAP AG. All rights reserved. 21
Digital Mining Enterprise:
Multiple-level Performance Management using SAP MII
Configuring the Views • Wizard to ensure consistency • Templates to simplify
configuration, drive consistency
Multi Site Performance Overview • High level view of multiple facilities • Integrated with corporate and supply chain
performance metrics
Site Performance Overview • Key metrics for primary areas • Raw, WIP, finished inventories • Key unit metrics – throughput, yields • Overall Equipment Effectiveness KPI’s • Asset Utilization KPI’s • Compliance KPI’s
Area Performance Overview • Key indicators for each area • Top items of interest by area – not all details • Identify key trends, forecasts
Production Performance Detail • Single asset/single issue root cause analysis • Production inventories / projections planning vs. actual key quality, yield forecasts
• Equipment / Machine Process overview graphic
Digital Mining Enterprise:
Integrated Short-Term Mine Scheduling Process
SAP ERP Mining Dynamics SAP MII Mining Production
Systems
Geological
System SAP BW
Mine
Model Detailed
Scheduling
Output :
Material
Quantity
Quality & Dates
Eq usage
Consumable
Usage
Utility Usage
BOM & Recipe
Input / Output
Resources
Utilization
Production
repository
Preventive
maintenance order
and planned
shutdown for
equipment
SAP Enterprise Portal Reports/KPIs (e.g. Plan v.s Actuals)
> Day/Shift
Last week’s/day’s
production
Fleet Management
Production Actuals
Runge’s Production
Planning & Scheduling
Mine Production
Execution
Master Data (e.g.
equipment,
capacity, cost rates)
Process Order
Real-time Reports
Create Confirmation
Actuals validation
Consolidate data from
ERP required for
scheduling
Plan validation
Create Process Order
Manage updated
version of the plan
Fleet Management
Schedule
Bring latest version of
the planned output
Manage plan change
request
No
Yes
Yes
Dispatcher Production Supervisor Truck Operator/Truck VIMS
VMIS/PCS
Record 1 of Truck1
Shift Report
Confirm
Process Order
VMIS/PCS
Record 1 of Truck2
Display of Truck2
Schedule/
Reschedule
VMIS/PCS
Record 2 of Truck1
Display of Truck2
Schedule/
Reschedule
VMIS/PCS
Record 2 of Truck2
Display of Truck1
Display of Truck1
Schedule/
Reschedule
Schedule/
Reschedule
Actual quantities per truck for current shift
Approve
Yes
No
Digital Mining Enterprise:
Integrated Short-Term Mine Scheduling Process
Digital Mining Enterprise:
Integrated Truck Maintenance Process: EXAMPLE
Dispatcher Maintenance Supervisor
& Planner Truck Operator
Notices Engine
Problem
Records
Engine Problem in
Fleet Management System
Create Work Order
Workorder confirmation
Production Supervisor &
Planner
Reschedule
Working Day based
on scheduled
Downtime
Reschedule
Available Fleet
Alert about Downtime Start
Automatic Record
in Fleet Management System
Alert about Downtime End
Automatic Recrd in
Fleet Management S.
Create Notification
in SAP System
Analyses problem on site:
Equipment Breakdown
due to Engine Failure
Work Order
Processing
incl. Planned Duration
ALERT into Dashboard
about
Equipment Breakdown
Update of Integrated
Production Plan based on
latest Equipment
Availability Plan
ALERT into Dashboard
about
Equipment Breakdown
END
© 2012 SAP AG. All rights reserved. 25
SAP
Plant Connectivity
Digital Mining Enterprise: Processing Plant
Enablement through SAP MII and Plant Connectivity (PCo)
SAP MII
Dashboard
Further
processing in ERP
Historian
SCADA
MES
LIMS
• Event trapped and
validated against
trigger criteria.
• Custom Notification
created and dispatched
to Destination.
• MII processes the event
message received from
Plant connector (PCo).
• All SAP MII capabilities
like dashboard, alerting or
further process trigger can
be enabled
Alerts etc.
Standards: OPC DA / AE / UA /
Socket
UDS
© 2012 SAP AG. All rights reserved. 26
Mine planning and
scheduling
Fleet Management
Metallurgical
reconciliation
CAT Minestar
Downtime
Recording
Reliability Centered
Maintenance
Asset information
management
IVN Facilitator
Implementation Partners
Mining Industry Council
Infrastructure and
Connectivity
Industry Value Network (IVN) for Mining Driving co-innovation with our customers & partners
Digital Mining Enterprise:
Infrastructure and Connectivity
Dimension
CISCO-SAP Collaboration Project
© 2012 SAP AG. All rights reserved. 28
Minimize risk & Maximize Security
Increase Asset Utilization
Support Environment & Regulatory Compliance
Maximize Employee Productivity
Improve Operations Management
Expand Visibility into Operations
Connected Mining Benefits
© 2012 SAP AG. All rights reserved. 29
CISCO Converged Plant Wide Ethernet ( CPwE) Architecture Industrial Networking
Customer Challenge
Multiple and disparate networks exist in many mining operations and there is growing
demand to integrate the networks to provide increased end to end visibility into the
production operations for the following reasons:
Increase of cyber threats for process control systems.
Abundance of COTS – Tools, Patches - All add to risk of security breaches
Increased demand to securely link operation and corporate networks.
Requirements for remote access, real-time, visibility, and post incident analysis.
Ability to capture forensic information to help troubleshooting and improve real-time decision making.
Optimize enterprise-wide operational performance and efficiency from disparate systems
© 2012 SAP AG. All rights reserved. 30
Tracking & Scheduling Logical Overview
Voice Video Data
Printer
PDA
GPS
DVR
Laptop
Video Cameras 2.4, 4.9GHz, or 5GHz
Uplink to Mesh Infrastructure Or 3G Cellular
Wireless Handset – ATEX (Zone 2/ 22) & CSA – IP64 Approved (7925EX)
Laptop
By utilising a unified standards based IP infrastructure
You can leverage multiple applications and services..
Improves:
• Operations
• Maintenance
• Safety
• Logistics
O
Win 2008
PI Interfaces
ISR-G2
Vmware VM’s
SRE-V /UCS-E
Win 2008 Sharepoint/Office
PI Server /Notifications
UCS-C/B
PLC/SENSORS
Remote Location Telemetry Aggregation via ISRG2/UCS-E
Hosted VM’s IE3000
IP Telemetry Asset
Win 2008 PI AF Server Process Book
Cisco Industrial Switches
Borderless Network
WAN
Public/Private Cloud
Remote Asset Asset Central Control Room
Control Engineer
On site Engineer
PI Visualisation tools
Example IWE Workforce Enablement channels
PI application and database Hosting on UCS
‘CEBT’
Collaboration Enabled Business Transformation
Business Process Logic
Application
Other Delivery Channels
Assets
© 2012 SAP AG. All rights reserved. 32
Connected Mining A Solutions Approach of CISCO
Customer Challenges
Solution Requirements
Engineering Design
Integration of Technologies
Validation & Implementation of Solution
© 2012 SAP AG. All rights reserved. 33
Prioritized Work Areas for CISCO-SAP Collaboration for
Mining Industry
1. Remote Operations Centers (ROC) enabled by CISCO infrastructure
AND SAP Manufacturing Integration & Intelligence (MII) solution
2. “Expert-On-Demand” solution using:
• CISCO’s “Remote Expert” (an umbrella solution with components like
Telepresence, Jabber, QUAD etc.)
• SAP HCM, Maintenance, Visual Enterprise solutions
3. SAP Incident Management enabled through CISCO Infrastructure
1. Remote Operations Centers (ROC)
Enabled by:
• CISCO infrastructure AND
• SAP Manufacturing Integration & Intelligence (MII) solution
© 2012 SAP AG. All rights reserved. 35
Digital Mining Enterprise: SAP Mobility with CISCO Infrastructure for Mine Equipment
Central Planning and monitoring Mine Site
SAP Business Suite SAP NetWeaver®
Central
SAP
Mobility
Server
satellite and GPRS
feeds
SAP
Mobility
running on
vehicle
CISCO
communications
equipment
running on
vehicle
© 2012 SAP AG. All rights reserved. 36
Video Wall – Remote Operations Centres SAP MII with CISCO
CISCO delivered live video feeds CISCO infrastructure collecting and
communicating sensor information
Collection
Aggregating information from various Sensors / Plant Automation systems and
transferring to SAP solutions using CISCO’s infrastructure (routers, switches, Digital
Media System-DMS, UCS etc.).
Visualization
Video Wall and individual PC production data visualization delivered using SAP MII and
Business Objects
© 2012 SAP AG. All rights reserved. 37
Tracking & Scheduling Mobile Equipment
Operational Efficiency
Operations Safety
• Scheduling Applications • Production Accounting
Maintenance
• Pro-Active & Predictive Maintenance
• Video Services • Expanded visibility for
truck drivers
Logistics
• Traffic Control • Locations based
services (GPS)
• Reduced costs for incidents and unexpected shutdowns
• Improves operational efficiency and productivity
• Increased worker productivity
• Better Visibility into Supply Chain
© 2012 SAP AG. All rights reserved. 38
For underground and open cut
mines, having flexible / mobile
control rooms and video
conferencing facilities is ideal.
The Video Wall picture on the
last slide would ideally be
displayed in the container.
The mobile control room can
also have quick access to
teleconferencing facilities.
SAP MII with CISCO Solutions for Mobile Control Room
© 2012 SAP AG. All rights reserved. 39
Bring a space optimised, ruggedized
“Kiosk” into crib rooms to provide
interactive services for:
Human Resources services from
SAP
Blasting times
Safety messages from SAP
Production plans and actuals from
SAP
Maintenance events from SAP
Shift status reporting from SAP
Delay accounting
… using CISCO’s Infrastructure
for data and video feed
SAP MII / Business Objects with CISCO Solutions
for Crib Room Services
2. “Expert-On-Demand” solution
Enabled by:
• CISCO’s “Remote Expert” (an umbrella solution with components like Telepresence,
Jabber, QUAD etc.) and
• SAP HCM, Maintenance, Visual Enterprise solutions
© 2012 SAP AG. All rights reserved. 41
Inspection Operator sees corrosion, uncertain if it is a real problem…uses mobile communicator to find expert…connects call
Cisco 7925-EX or
Smart Phone
Integration with UC
and Mobility
Video Equipment Inspection Based on: Field Mobile Video service
Upload to Cisco Webex
Social for Show and
Share - Replay Voice &
Video for knowledge
transfer
Value
• Reduced time to evaluate critical and non critical issues
• Reduction in downtime due to better decisions and leveraging remote experts
• Reduction time to intervention on drilling * avg cost/hr of drill rig
• Reduction of risk of incidences vs. average cost per incident
Cisco Cius (Not
ATEX Rated)
ATEX/CSA rated
(zone 2)
… Using hand held wireless EX camera, has collaboration session with experts, recording where needed
© 2012 SAP AG. All rights reserved. 42
SAP Mobile Solutions with CISCO for Maintenance and Production
Embed CISCO “voice calling”, “video feed”
and “CISCO Webex social networking
functionality” into SAP Syclo Mobility
solution for access to expert-on-demand
for:
1. Visual Inspection and advice
2. Maintenance Processing
3. Production scheduling
3. Mine Safety solution
Enabled by:
CISCO Infrastructure and
SAP Incident Management
© 2012 SAP AG. All rights reserved. 44
• Regulatory Compliance (Safety, Labour, Environment)
• Reduced costs for incidents and unexpected shutdowns
• Improves operational efficiency and productivity
• Increased worker productivity
Connected Mining Information System Collaboration & Visibility
Safety & Operational Efficiency
Corporate Messaging Point of Use
• Executive announcements
• Company Information
Live Video
• One to many Messaging & Video e.g. Entertainment
• Safety Warning’s • Production Data, Status
& Statistics
Video on Demand
• Operational procedures (Set-up)
• Training
Thank you
Contact information:
Nikhil Chaturvedi
Director, Global Lead – Mining, IBU-Mill Products & Mining
SAP Asia Pte. Ltd., Singapore
+65-97393866
© 2012 SAP AG. All rights reserved. 46
© 2012 SAP AG. All rights reserved.
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