Operations Control X-Cellence

Implementation Award Category: Monitoring and Control X-Cellence

Last year at the AVEVA IS3 X-Change User Conference, Mafube Coal, together with Rifle-Shot Performance Holdings (RSPH) and Industry Software Solutions and Support (IS3), also known as AVEVA Select Southern Africa, won the award for Best Business Value (ROI), presented by Industry Software Solutions and Support (IS3), also known as AVEVA Select Southern Africa,. This was based on the benefits realized by Mafube Coal during Phase 1 of their Transformation Journey. They are now able to instantaneously identify and remove obsolete line items and can focus all attention on what is relevant to top and bottom-line impact.

The Downtime Module has been fully implemented and in use since 8 April, 2024. This year, we showcased the benefits the Downtime Module is providing, looked back at lessons learned and provided a glimpse into the future on Mafube’s next Phases: Production Tracking and Quality Reporting. The goal is Monitoring and Control X-Cellence.

AVEVA Production Management is a comprehensive MES/MOM platform for continuous processes that connects directly to the plant information systems and reports in near real-time on Production KPIs. The solution consists of several modules: Downtime, Production, Quality, Metrics, Energy, Inventory, Knowledge, Planning and Maintenance.

The automation of Downtime Tracking means the removal of manual data capture, formalized processes and ease of reporting. Selection of pre-defined causes for downtime ensures standard classification for accuracy and ease of trend tracking, ensuring responses are quick and correct.

The Downtime module enables users to make better decisions by digitising three core functions. Firstly, data collection i.e. automating (manual data entry also allowed) the creation of downtime events when the plant is standing or performing below specification. Secondly, formalising the editing and validation of downtime events. Downtime events are classified, and causes assigned according to a configured matrix based on the equipment responsible for the downtime event. Lastly Production Management allows for the easy view and analysis of this now digitised information.

In Mafube’s case AVEVA Production Management interfaces with Mafube’s plant SCADA system via an AVEVA Historian. Downtime events are created based on the run state and rate of key equipment within the plant. These are then validated and classified by Control Room Operators directly on a terminal within the Control Room. Metallurgist, production-, maintenance-, planning personnel and management can then analyse and summarise the captured data from their own terminal to inform better decision making and take action to reduce downtime.

On the Front End, the Downtime Module is linked to key equipment, particularly conveyors, with Start/Stop Indicators which alert the production team to unscheduled stoppages immediately. In the DMS Plant, the weightrometer measures whether the throughput is in fact a minimum of 930 tonnes per hour, if not, production is noted as ‘slow running’. Overland, between rail and trucks, there are over 30 kilometres covered – from stockpiles to reclaimers and conveyors, all of which have sensors along the route – measuring running pace and throughput.

The project is not without challenges the foundation however has been laid and the lessons learned will be applied with the second phase, Production Tracking, which is in the process of being approved and the third phase of the journey already being identified as integration of the quality / lab data.

The progress made so far is a testament to the combined experience and passion the respective contributors bring to this project. The team consists of:

• Martin Maeriën, RSPH Specialist ResultantTM, who is the lead on this project and has vast experience in Value Chain Optimization & Visualization;
• Madelein Huxtable, RSPH Project Manager Extraodinaire;
• Tshepiso Mapoulo, Mafube Digital Value Chain Lead and
• Pilwane Matlala, Metallurgical Engineer and Subject Matter Expert – Pilwane has been key to the success of every design session
• Devan Pillay, IS3 Project Manager
• Paul Kotze, IS3 Solution Architect and
• Cornu Perold, IS3 Account Manager

Critical to the success of this project has been trust, humility and cooperation of all contributors… Onward and upward!

“What an honour to be serving Mafube Coal this way – a true win-win-win partnership between IS3 also known as AVEVA Select Southern Africa and RSPH.” – Dion Govender, CEO Digital Industries and MD IS3