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BXT Session - Digital Champions in the Mining & Processing Industry

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Page 1: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

BXT Session - Digital Champions in the Mining & Processing Industry

Page 2: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Our Digital Operations framework covers all key operations & support functions and technologies in a mine

2

Connected Supply Chain

Smart Operations

Digital Maintenance

Health, Safety, Security &

Environment

Digital Twin Plant Excellence

Digital Support Functions

IT/Technology

Architecture

Digital Capabilities

& CulturePartnership &

Alliances

Governance/Processes

and Data Management

Information

Risk

Management

DIGITALIZATION OF SUPPORT FUNCTIONS

Enablers:

Connected Supply Chain

MetalProcessing

Digital Maintenance

Integrated Planning

Health, Safety, Security & Environment

Digital Mining

Digital Support Functions

Augmented reality

PwC’s Digital Services

Exploration

Smart Operations

Page 3: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Digital Champions create value through integrated ecosystems with double-digit revenue boosts and efficiency gains

3

Benefits investing in digital technologies and Digital Champion Solutions – Process Industry

13%

Digital Novices vs.

Digitization of product and service offerings1

2

4

5

Leadership in customer-centric solutions

+

7

Near real-time E2E integration & planning platforms

Full vertical integration / MES of manufacturing operations

Digital Strategy & implementation roadmap

8

Digital experts and dedicated training programs

3Management of a partner solution network

6Tech innovations, e.g. Al Solutions, Collaborative Robots

Digital Revenue Increase

2018 - 2023

8%

23%Efficiency Gains /

Cost Reduction 2018 -2023

11%

Digital Champions

Confidential information for the sole benefit and use of PwC’s client.

Page 4: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Predictive maintenance at downstream process manufacturerS

en

so

r-a

nd

rem

ote

dia

gn

os

tic

s

Remote control towerData collection On site

Fully digitized process

Remote

Mobile information

Pla

nn

ing

Ala

rm

Ma

inte

na

nc

e &

rep

air

A large downstream manufacturer collects and analyzes operational data that allow for predictive maintenance, remote monitoring & digital repairs

14

Smart Algorithms

CLIENT EXAMPLE

Page 5: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Drone and robot technologies are applied to support maintenance processes in the mining and oil & gas infrastructure

5

Best Practice Examples – Digital Maintenance & Repair

Source: Desk research, Client examples, Strategy& analysis

Pic. 2. Drones for Leak detection

Pic. 1. Corroded elements identified

Pic. 3. Maintenance roboter in uses

• Maintenance of assets, e.g. structural

assessment of technical conditions

of various infrastructure elements,

structural alignment validation,

detection of overheating elements and

corrosion

• Leak detection with no ability to see

the leakage on often long- stretching

or difficult-to-reach pipelines

• Engagement of workforce in potentially

dangerous areas posing a significant

health and safety risks

• Drone-borne infrared sensor enable

automation and acceleration of

maintenance issue identification

• The initial assessment and

correction of the situation can be done

immediately based on real-time video

stream and robot tools

Pic. 4. Self driving robot in mining

maintenance

CLIENT EXAMPLE

Page 6: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

3. Operations

Mobile solutions for plant operations

1. Maintenance

Mobile Maintenance solutions

4. Engineering

Mobile access to engineering data

2. Turnaround

Special maintenance

Augmented reality solutions have been implemented by a client in the process industry to optimize operations and maintenance

Connect physical assets to digital world

Enable identification of equipment

Receive performance and quality data in real time

Enable equipment alarm settings and remote diagnostics

Enable equipment visibility and location tracking in complex plants

Provide critical service data for equipment

Push work instructions to reduce time and knowhow requirements for service

Establish optimized user interface, task confirmation and service documentation

Objectives of Augmented Reality

Client example

6

CLIENT EXAMPLE

Page 7: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

AR Platform Framework

Sub Platform for SAP based AR solutions based on SMP

(SAP Mobile Platform)

SAP/PM PIMS (prod. inf. mgmt. system) DCS (distributed control system) others

Sub Platform for PIMS based AR solutions(vendor tbd)

Sub Platform for DCS based AR solutions

(vendor DCS specific)

others

Interface Interface Interface Interface

Apps Store + Apps

Digital technologies have been implemented to enable mobile communication and AR solutions

Augmented Reality SolutionWireless Plant Infrastructure

AR as a

Global Service

Se

rvic

e

Client example

7

Mobile Devices &

Mobile Device Management

CLIENT EXAMPLE

Page 8: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Overview

• 3D digital asset information data capture by scanning (drones,

autonomous underwater vehicle (AUV) and scanners) and

providing centralized management of all available field data

• Web-based 3D view of site stored in the Single Point Of Truth

database allow for Single Panoramic Images; Walkthrough /

Flythrough; Asset Tagging etc. Siemens software is used to train

its staff for offshore installations using a virtual 3D environment

• The simulator offers a virtual 3D environment of a plant and

provides the opportunity to simulate real-life situations, allowing

workers to see and experience what tasks they need to perform,

and rehearse procedures and workflows associated with any

number of scenarios.

Benefits

• Increased transparency for brownfield works

• Risk mitigation and increased safety

• Operational Cost and Downtime Reduction

• Reduction of maintenance time & cost 8

Global Process leader trains its field operators in a 3D virtual environment to ensure higher safety procedures and reduce operations cost CLIENT EXAMPLE

Page 9: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Advanced MES planning tools integrate and optimize all operations management functions

9

Dynamic detailed planning & scheduling

Business Planning and Logistics

Production Control and Process

Sm

ar

t V

isu

ali

za

tio

n

Asset configuration

Resource availability

Location / track & trace information

Quality / NCM

information

Inventory levels (RM, WIP, FG)

E2E network capacity and availability

Supplier (plan+order)

Process quality

Product quality

Maintenance Management

Sensor/ actuator data

Ve

rti

ca

l In

teg

ra

tio

n

Customer demand

(plan+order)

Horizontal Integration

Sales & Operations Planning

ProductionOperations

Management

QualityOperations

Management

MaintenanceOperations

Management

InventoryOperations

Management

CLIENT EXAMPLE

Page 10: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

MES Digital cockpits allow for real time controlling and optimization of operations processes

Collaborative planning solution

CLIENT EXAMPLE

Page 11: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Digital Operations Impact Center - Playbook

An integrated end-to-end planning is based on a joint platform for all planning-related activities between key functions

11

CustomerSupply Integrated planning &

execution platform

E2E supply &

demand planning

Integrated planning and

execution along the

value chain

Integration into B2B and B2C

ecosystem (PoS data & public data,

online market places, own apps,

customer ERP integration)

Proactive demand

sensing

Utilization of digital

customer and

configuration data,

sales data, service

needs and external

data

E2E logistics visibility

(Last mile notification,

E2E tracking)

Enabler

E2E data availability, utilization and analysis & efficient IT and data architecture as supply chain support

Integrated material

requirements planning (VMI/

consignment stock, visibility on

inventory)

Vertical integrated

real-time planning

in production

incl. MES

introduction

End-user

Customer

Warehousing

Tier 2 Supplier

Tier 1 Supplier

Production

client

client

client

Service

Dynamic real-time inventory

management for a multistage

SC and warehouse network

Industry case

Globally leading player using cloud

ERP solution to create a supply

chain ecosystem

• Using a cloud collaboration platform to

link all stakeholders from suppliers

through internal operations to customers

• Near real-time feedback on changes in

customer demand or product availability

assessed and communicated along the

supply chain

• Integration with different legacy planning

solutions and logistics platforms

Supplier Production Distribution Customer ConsumerExt. data

sources

Cloud

based

Confidential information for the sole benefit and use of PwC’s client

CLIENT EXAMPLE

Page 12: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Live inventory location and stock level tracking & optimization management has been installed to optimize inventor levels

Fully integrating IBM Maximo with the warehouse

management system for seamless workflow and

real time data analytics

Access control

system

Use of RFID / barcode based scanners

for inbound and outbound material

movement, with automated track and

trace capabilities

- Forklifts with scanners which directly receive pick lists

- Rail-guided Very Narrow Aisle (VNA) storage trucks

- Man-to-goods systems (wide aisle Pallet storage,

racking system with bins and cantilevers)

- Goods-to-man system (vertical carousal system)Access control system and

CCTV for monitoring

warehouse and inventory

Monitoring & Surveillance

(Level 2)

Material Inspection &Tracking

(Level 2)

Systems / IT

(Level 3)

Put-away, Palleting, storage and packing

(Level 2)

Maximo – WMS WMS – Resource (Labour / smart forklift)

Create work order Generate picklistReceive picklist by

resource

Schedule

maintenanceFulfil order

1

2 34

Seamless workflow of warehouse processes

WMS

Integration of Maintenance

CLIENT EXAMPLE

Page 13: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

PwC Strategy&

Implementation of a Smart Site Management using an Integrated Supply Chain Tower

13

Control Tower activities

• Just-in-time / Just-in-sequence

delivery

• Detailed operations scheduling

(FTEs and equipment)

• Fleet management &

optimization

• Maintenance management

• Dynamic project management

& scheduling

• Big data analytics for

performance data

• Integration of suppliers (incl.

services)

• Optimal on-site routing

• Autonomous operations

(control room)

• Smart site technologies for in-

and outbound logistics

• Automated and fully

transparent tracking

Automated

warehousing

Shipment

tracking

Smart

conveyors

Augmented

picking

Smart

returnable

packaging

Off site

hubs/

terminals

Site pipe management

Automated

loading

and unloading

Mobile

access

ALER

T

Rail yard

management

Site access mgmt.

Off site On site

Autonomous vehicles

Just-in-time delivery

Operations

scheduling

Fleet

management

Drone-based site

measurement

Connected supply chain Control Tower

Track & trace

Customer

Supplier

Tra

ck &

trace

Tra

ck &

tra

ce

Distribution

Production

Flow of goods

Flow of information

Dynamic demand

sensing and integrated

forecasting

E2E supply & demand

planning and

execution

E2E supply chain and

operations visibility

Automated data

analyticsHolistic supplier management and

collaboration

CLIENT EXAMPLE

Page 14: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

A best practice IT architecture covers all elements to enable the implementation of digital applications

14

Data sources, physical processes

Users

Access channels

Presentation(view)

End to end security

IT o

pera

tio

ns m

anagem

ent

Analy

tics, B

I and r

eport

ing

Data

retrie

val and a

ggre

gatio

n

serv

ices

Data

retrie

val and a

ggre

gatio

n

serv

ices

Centralized data management

Client management and staff Client service providers

Web browser M-browser Mobile apps E-mail SMS AR / VR

Website Application portals Dashboards Template management

Multi-lingual support UI personalization Content management Channel specific rendering

Monitori

ng

and a

lert

serv

ices

Syste

m

health

dashboard

Tic

ket/

defe

ct

mgm

t.

Configur-

ation m

gm

t.

Loggin

g/

trackin

g

mgm

t.

Ris

k

analy

tics

End to

end

analy

tics

Org

. P

erf

. A

naly

tics

Self-

serv

ice B

I

Syste

m

usage

and p

erf

.

Fore

cast

Capacity

Pla

nnin

g

Busin

ess

report

ing

Fin

ancia

l

analy

tics

Inte

gra

tio

n m

anagem

ent

AP

I

managem

ent

Managed

FT

P

Inte

gra

tion

dashboard

Clo

ud

Inte

gra

tion

pla

tform

Tra

nsla

tion

and E

TL

schedulin

g

Business services / components layer

Client Business Enabling Solutions

• MOM (Manufacturing Operation Management)• Inventory Management • APM• Procurement suite

• Condition Monitoring• Predictive Maintenance• Permit to work• HSE drones

Client General Purpose Solutions

Client business services and administration functions

Endpoint security

Cyber security

Application and data

security

Identity and access

management

Network security

Physical access

security

Data centre security

Security audit and

compliance

Desktop virtualization

Remote access

management

Data Abstraction Layer MDM database Transaction database Process historian Analytics database Audit database Reporting database

Physical IT infrastructure IT applications

Server infrastructure Network infrastructure Peripheral devices Security devices Business applicationsEnabling / shared

system appsIT delivery and support

mgmt. appsIT security apps

• Collaboration solution• Workflow management

• IT service activation• Knowledge management

• Strategy and performance tracking workflows• HR and training solutions• Account and finance solutions• Legal compliance and case mgmt. solutions

• Contract mgmt. solution• Capital – Investment management solution• Risk assessment and management solution

Recommended IT Architecture

CLIENT EXAMPLE

Source: Strategy& analysis

Confidential information for the sole benefit and use of PwC Strategy&’s client

Page 15: Digital Champions in the Mining & Processing Industry · •3D digital asset information data capture by scanning (drones, autonomous underwater vehicle ... •The simulator offers

Empowered employees and the right strategy are at the center of digital transformation

“Our company has

flat hierarchies that

facilitate agile working and

quick decision-making.”37%

“We are focused on

providing a digital

customer experience

throughout the

customer journey.”35%

“Our leadership has

a clear digital vision and

strategy for the digital

future and acts

as role model.”34%

“We foster a culture

of innovation with multi-

disciplinary teams.”

“Our employees have the

required qualifications for

the digital future.”

“We have invested

heavily in training

to make our staff fit for digital

transformation.”

27%

26%

Digital Strategy Digital Organization Digital Education

32%

15Source: Global Digital Operations Study, Strategy& analysis

Corporate Digital Vision and Culture