controlling costly equipment maintenance in mining sector · as the preferred vendor and...
TRANSCRIPT
Controlling Costly
Equipment Maintenance in the Mining
Industry
Hardcat empowers the mining sector to embrace technology, unlock opportunity and improve worker safety
M i n i n g se c t o r
The mining industry poses another unique challenge. Its workers operate large complex equipment, in some climatically hostile and extreme environments. With this mixture, mine maintenance is no easy venture.
The typical mine maintenance manager has to contend with many issues including continuous machine repair, aging equipment, reduced funds, and worker safety concerns.
Mining accidents are on the rise, with eight mining deaths recorded in the last two years (QLD, Australia). Late last year (2019) the state government vowed to get tough on mining bosses who fail to protect their workers.
Under a bill to be considered by parliament this year, mining operators could be jailed and hit with hefty fines for deaths on their mine sites. The government announced plans to create an industrial manslaughter offence for the resources sector. The charge would carry a maximum 20-year sentence for company heads and fines of up to $10 million for firms found to have been negligent.
The mining union CFMEU’s Queensland president Stephen Smyth said in a statement. "This is a terrible start to 2020. The industry must redouble efforts to end the tragic loss of life in our mines."
The mining and resources sector are by nature a highly complex industry. Its processes and operations are intensive, risk-prone, and subject to uncontrollable weather conditions.
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www.hardcat.com
M i n i n g se c t o r
BHP Billiton Nickel West - case study
The organisation
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BHP Billiton Nickel West identified a major WHS/OH&S risk at the Kalgoorlie Nickel Smelter with the issuing, returns and maintenance of respirators for their mining staff.
BHP Billiton Nickel West is a fully integrated, world-class nickel producer with a commitment to Zero Harm and sustainable development. BHP Billiton Nickel West is the world’s third largest producer of nickel-in-concentrate.
With excellent infrastructure and a focused leadership team, BHP Billiton Nickel West exports around 100,000 tonnes of nickel in metal each year, employs more than 3400 operational employees and contractors. BHP provides significant benefits to the Western Australian economy and to the communities in which it operates.
The issues
No definitive record of who was issued which respirator(s)
The possibility of incorrect or faulty respirator units being issued to workers
Critical respirator maintenance being overlooked or incorrectly completed
www.hardcat.com
BHP Billiton Nickel West was also unable to identify the actual cost of the maintenance on this equipment and therefore unable to charge this back to the appropriate cost centre.
M i n i n g se c t o r
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"Hardcat has significantly streamlined the issuing, returns and maintenance requirements for respirators within a storeroom environment”
"All this was achieved while at the same time addressing the initial WHS/OH&S concerns”
BHP Billiton Nickel West's Hardcat solution allows workers to efficiently and effectively manage the issue, return and maintenance of respirators for their mining staff while addressing the WHS/OH&S issues.
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BHP Billiton Nickel West - Hardcat solution
The standard configured Hardcat solution addressed all of BHP Billiton Nickel West WHS/OH&S issues, and provided maximum speed and accuracy when issuing, returning and maintaining these respirators within a storeroom environment.
Hardcat was configured to provide a number of specific reports which addressed BHP Billiton Nickel West’s WHS/OH&S compliance requirements.
Following an extensive evaluation process, Hardcat solutions were selected as the preferred vendor and implemented a solution based upon:
• Asset Management module
• Stock module
• Maintenance module
• Barcoding
• HardcatWeb Interface modules
Grind down yourmaintenance costs
Köppern roller presses have been proven successful throughout the world in plants specializingin the cost-saving high pressure comminution of various ores like iron, copper, gold, diamond,molybdenum and lithium ore. The Köppern Hybridur® tires feature an extremely wear-resistant surface that provides enhanced roller protection when grinding abrasive ores.
Köppern – Quality made in Germany.
State of the art HPGRs and wear protection
Process technology know-how
High plant availability
Low maintenance cost
Pilot HPGR testing capabilities in Australia, Canada, Germany and Russia
For further information please [email protected] www.koeppern.de
M i n i n g se c t o r
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www.hardcat.com
BHP Billiton Nickel West - Hardcat implementation
1. One version - single source of truth2. Better leverage equipment suppliers3. Time efficiencies and solution ease of use
The implementation of the Hardcat solution addressed the WHS/OH&S issues around the management of respirators. Hardcat's continued use has promote greater efficiencies and time-savings, enabling staff to dedicate more of their time to other aspects of their jobs.
One version - single source of truth
BHP Billiton Nickel West have the benefit of a comprehensive asset register which provides clear accurate visibility of their assets and equipment while providing highly detailed tracking of all maintenance work carried out on these assets.
Leverage equipment suppliers
BHP Billiton Nickel West now have a detailed database with accurate historic logs and up-to-date information. This enables future leverage of supplier relationships and warranties.
Solution ease of use
The Hardcat solution at BHP is very popular with workers primarily because it is easy to use and they can see the benefits it brings to their jobs and safety. As as a result, employees have been quick to embrace its use.
M i n i n g se c t o r
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www.hardcat.com
ADNOC (GASCO) - Hardcat solution
The organisation
ADNOC Gas Processing (formerly GASCO), a natural gas producing company of Abu Dhabi. The company uses Hardcat solutions to track the usage of over 6000 tool assets in 319 categories by 287 staff in the centralised tool room of its Habshan 5 Plan in UAE. The tools range from small hand tools to chain hoists and large scale maintenance equipment.
The issues
• Reduced time to perform workshopaudits by 80%
• Reduce time to perform issue andreturns by 90%
• Reduce time to produce tool usagereporting by 80%
• Ability to reports on complete audittrail of individual tools and equipment
• Monitor consumable stock and spareparts, usage and store levels
• No formal asset register software• No asset tags or markings• No automated way of tracing which
employee ID is issued what item• No product categorization• No issue and return history against each
item• No system for inventory or maintenance
audit• No standard list for location and people• No automated identification of employee
whom the asset is issued• Spread sheet asset register has no
security• No system transaction history available
- who did what?
Hardcat implementation
Grind down yourmaintenance costs
Köppern roller presses have been proven successful throughout the world in plants specializingin the cost-saving high pressure comminution of various ores like iron, copper, gold, diamond,molybdenum and lithium ore. The Köppern Hybridur® tires feature an extremely wear-resistant surface that provides enhanced roller protection when grinding abrasive ores.
Köppern – Quality made in Germany.
State of the art HPGRs and wear protection
Process technology know-how
High plant availability
Low maintenance cost
Pilot HPGR testing capabilities in Australia, Canada, Germany and Russia
For further information please [email protected] www.koeppern.de
"Adopting RFID technology saves organisations time and money while also providing comprehensive visibility on equipment utilisation.”
M i n i n g se c t o r
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www.hardcat.com
RFID – making mining safe, secure and more efficient
Many leading organisations are taking advantage of RFID’s capability to deliver benefits such as real time asset tracking, instant bulk auditing and comprehensive governance and compliance over the full life-cycle of individual assets.
Adopting RFID technology saves organisations time and money while also providing comprehensive visibility on asset utilisation.
RFID and fixed readersFixed readers for doorways and choke-points. Hardcat’s Sentinel software allows for automatic registering of both assets as well as workers.
RFID worker auditWorker audits ensure that personnel are kept safe and accounted for. It can be as simple as allowing only identified staff into certain locations.
RFID and CCTV
RFID triggering CCTV images is an important deterrent in areas without physical security. Fixed RFID readers installed at prominent entry and exit points (unmanned or manned locations) will automatically detect assets and workers moving in and out of these doorways and chock-points.
ADGASAdvantage Petroleum T/S Shell Direct (NSW)BHP Billiton Iron Ore Pty LtdBHP Billiton Nickel WestBHP Billiton NW - Kalgoorlie Nickel SmelterBHP Billiton Uranium SACITIC Pacific Mining Management Pty LtdDerfell Pty Ltd T/A Shell Direct (Vic/Tas)Fuelink Pty Ltd T/A Shell DirectGASCOGASCO HabshaanINPEX Browse LtdInsert actual Company Name hereInsert actual Company Name hereINTECSEALaing O'Rourke AustraliaMinara ResourcesNational Petroleum Investment Management Services
Ok Tedi Mining LimitedPilbara Iron CompanyPilbara Iron Company (Services) Pty LtdPilbara Manganese Pty LtdQatar PetroleumQueensland Mines Rescue Service Ltd QMRSRio Tinto Cape LambertRio Tinto MarandooRio Tinto Rail Network MaintenanceRTIO Resource DevelopmentSantos (SAMPANG) PTY LTDShell Direct (Sungold)Shell Egypt N.V.Syria Shell PetroleumTullow Ghana LimitedVivoEnergyYem TechnologyZinifex Century Mine
Mining sector clients
Hardcat specialises in asset and equipment management software and services. Utilizing the very latest technology such as passive RFID, optional web front ends, wireless and GPRS PDAs and apps for asset management in the field. While offering the certainty of success that only comes with an established product.
Hardcat software has been sold to literally thousands of the world’s most prestigious corporate and government entities in more than 120 countries worldwide, and there are Hardcat representatives based in every corner of the globe.
Australia (HQ)
Hardcat House 253 Park Street South Melbourne VIC 3205
p: +61 (0)3 9695 5400
USA
701 South Carson Street Suite 200-3824 Carson City NV 89701
p: 702-589-5839
South Africa
Country Club Estate 21 Woodlands Drive Woodmead Johannesburg 2191
p:+27(0)82785 2747
UK
Unit 4 Lansbury Estate 102 Lower Guildford Road Knaphill Woking Surrey GU21 2EP
p:+44(0)7713 152499