Maintenance Solutions For The Mining Industry: Activities To Date

Maintenance
Solutions for
the Mining Industry
Dean Fitt SAP AG

IBU Mining
Introduction
Î Activities to date
Current Activities
Future/Planned Activities
 SAP AG 2002, Title of Presentation, Speaker Name 2
1
Mining Solution Map 2002
Strategic Enterprise Business Intelligence & Workforce Planning &

Enterprise Management Business Analytics Accounting
Management Decision Support Alignment
Customer Relationship
Customer Engagement Business Transaction Order Fulfillment Customer Service
Management
Acquire & Develop Explore Prospect Acquire Resource Develop Resource Commission Operation
Mining & Primary Asset Lifecycle

Mining Primary Processing Internal Logistics Inventory management
Processing Management
Asset Lifecycle
Secondary Processing Acquire Feedstock Secondary Processing Tertiary Processing Internal Logistics
Management
Sales & Distribution Sales Outbound Logistics Assay Handling Invoicing
HR Operations Treasury/
Financial Supply Fixed Asset Environmental
Business Support Sourcing & Procurement Corporate Finance
Chain Management Management Health & Safety
Deployment Management
Scope of Best Practices for mySAP Mining (4.6C)
List of Scenarios
Work Clearance
Management 17
17 11 Production
22 Scheduling
Refurbishment of a 16
16
Serialized Material Capacity Planning
15
15 33
Corrective Product Costing
Maintenance 44
14
14
Preventative ROM Production
Maintenance 13
13 55
End of Period -
Concentrate Sales – Physicals
with Quality Mgt 12
12 66
Concentrate Sales – Inter Plant Bulk
Freight Costing
11
11 77 Transportation
ROM Stockpile
Concentrate Sales – 10
10 88 Blending
Complex Pricing 99
Concentrate Sales Concentrate Blending Concentrate

Production
2
Preventive Maintenance
Preventive
Preventive
maintenance
maintenance
Time-based
Time-based Performance-based
Performance-based Condition-based
Condition-based
2000
30 40 50
20 60
10 70
80
Pressure
Pressure
Temperature
Tread Depth
Unplanned Maintenance: Work Order Overview
1 Notification • Technical object • Date

• Description • Malfunction
2 Planning • Operations • Material

• Internal/external resources • Tools
3 Scheduling • Order release • Capacity leveling

• Shop Papers • Availability check
4 Execution • Planned/unplanned material withdrawal

• External procurement
5 Completion • Time confirmation • Order settlement

• Technical completion • Technical confirmation
History
Material usage, orders, notifications, PMIS, usage list
3
Unplanned Maintenance: Web based Notification
Refurbishment Process for Major Components
Articulated Dump Truck
Engine
Major Components
(Sub-Equipment)
Differential
Torque Convertor
4
Refurbishment Process (Two Order)
Order No 1: Repair Order Process
Notification
Rotables Store
Repair Order
Install
Dismantle
Order No 2: Refurbishment Order Goods Issue of

Defective Item (C3)
Process Goods Receipt of
(this is the process covered by Best Practices for Mining) Refurbished Item (C2)
Refurbishment
Order
Defective item sent
Material No
for repair to external Serial No
contractor or internal
workshop
Refurbishment Process
Value Business Maintenance Maintenance Business Value
Storeman
Potentials Benefits Engineer Planner Benefits Potentials
Up to 20% less Refurbishment Prevention of Up to 20%
time for overall integrates Replace faulty unnecessary reduced costs
replacement equipment in equipment down-times due by streamlined
process* the material to high stock
master Post to stock with availability of management*
condition-based value operational
Condition-
equipment
based valuation
in material Store equipment Streamlined
master refurbishment
process
Up to 30% time Condition-
savings in based stock Create and release Easy stock Up to 100%
refurbishing management refurbishment order monitoring certainty that
process* including sufficient
accurate stock operational
value Receive equipment Withdraw equipment equipment is
available on
Easy-to-plan
stock*
and easy-to-
schedule Refurbish equipment * Discussions with Customers
refurbishment
Make confirmations
for order
Complete
refurbishment order
Post to stock with

new condition-based
value
5
Work Clearance Management (WCM)
Operational
WCD
3212345
WCM: Maintenance Processes
Work Clearance
Maintenance plan
Management
Create Plan Release Confirm Complete

Notification
Order Order Order Order Order
Analyze Histories
Work Clearance
SCADA
Management
6
Capacity Planning: Production Requirement
X XXX X X
X XXX X X
X XXX X X
Production capacity requirements are generated from planned and

production orders and are placed on production resources
Capacity Planning: Maintenance Requirement
Maintenance capacity requirements are generated from Maintenance

Orders, which are usually raised against Equipment master records.
The Equipment master is linked to the relevant production resource
7
Capacity Planning: Planner’s Perspective
X XXX X X
X XXX X X
X XXX X X
X
The planner can see the impact of the Maintenance

requirement and adjust the production plan accordingly
Maintenance Solutions for the Mining Industry
Activities to date
Î Current Activities
8
Maintenance Cost Planning: Problem Statement
In core SAP R/3, we cannot effectively link maintenance

strategy with budget and actual costs. We are therefore
unable to determine the effect of our maintenance
strategy in achieving our business goals and measures.
For example:
Cannot budget at a technical object level
Cannot compare budget and forecast
Cannot determine if we are deploying the "right" strategy
Unable to determine work centre responsible for work
Maintenance Cost Planning: History
Long standing requirement from mining customers
One of the top requirements from IACM
High Level Requirements received
Investigated various options
SEM-BPS identified as suitable tool
Prototype developed in SEM-BPS
Presented prototype at April IACM meeting
Workshops held in Melbourne and Johannesburg
Development Request received beginning June
9
Maintenance Cost Planning: Prototype
Based on SAP SEM-BPS
Prototype Overview
Prototype: SAP SEM Strategic Enterprise Management
Strategy Management Performance Business Consolidation Business Planning Stakeholder

Measurement Legal & Mgmt Cons. Relationship
■ Balanced Scorecard ■ Modelling
■ Management Cockpit Management
GAAP Adjustments
■ Risk Management ■ Planning Framework
■ Measure Builder ■ Contact Mgmt.
Currency Translation
■ Value based Mgmt. ■ Planning
■ Measure Tree Analysis ■ Stakeholder
Interunit Eliminations Applications
■ Strategy Templates ■ Benchmark Integration selfservice
Cons. of Investments ■ Simulation
& Analysis ■ Stakeholder
Restatement ■ Planning Process reporting
Organizational changes Coordination
SAP BW & KW
10
Prototype: SEM-BPS User Interfaces
Web
based
based Interfaces
Interfaces
HTML / ITS Web Interface Builder Survey Technique
Excel
based
based Interfaces
Interfaces
SAPGUI Excel-In-Place Excel Client
SAPGUI
based
based Interfaces
Interfaces
Planning Folder ALV Grid
Third party
based
based Interfaces
Interfaces
Powersim OROS / ABM
Prototype: Reporting and Analysis
SAP SEM Pefomance SAP SEM Management Cockpit

Measurement
SAP BW-Alert Reporting SAP BW-Excel SAP BW-Web Reporting

Reporting
Danger!
11
Prototype: Maintenance Cost Planning
Identify Maintenance Activities (Maintenance Plans, Task Lists
1 & PM Orders). Extract from SAP R/3 to SAP BW
SAP R/3 SAP BW
Copy of extracted data into transactional SEM Cubes

2
SAP BW
Develop Maintenance Cost Plan in SEM-BPS (based on

3 quantity, frequency, timing and probability of activities)
SAP BW
Retraction from SEM-BPS to SAP R/3 (if required)

4 SAP R/3
Prototype: Scope
Based on:
Technical Object for:
Planned Maintenance
Unplanned Maintenence
BUDGET
BUDGET Control
Control
Compare VARIANCE
VARIANCE
Reporting
ACTUAL
ACTUAL Forecast
Forecast
Actual Costs incurred:

Labour
Materials
Other
12
Protoytpe: System Landscape
SAP R/3 System DRC SAP BW System DHB

(IS Mine Demo) (filled by extraction) SAP SEM System DHY
&RVW (OHPHQW
&RVW FHQWHU
)LVFDO \HDUSHULRG
)LVFDO \HDU YDULDQW
)XQFWLRQDO /RFDWLRQ
0DLQWHQDQFH 2UGHU
30 0DLQWHQDQFH 3ODQW
30 SODQQHU JURXS
30 SODQQLQJ SODQW
3ODQQHG &XUUHQF\
3ODQW
0DLQW :RUN &HQWHU
30 2UGHU 3ODQQHG &RVW
&RQWUROOLQJ $UHD
Prototype: Concept
1) Identify Technical Objects e.g. by Superior FL, CC, Planner Group

Functional Location or Description
Equipment Number
01MI-MP12-2000-001-HTR0001 Haul Truck D400-001
2) Develop Cost Plan

Functiona l Loca tion or TL Type TL Group Group Cnt De scription Pla n Cost Fre que ncy Add Allow a nce Tota l Pla nne d Cost
Equipm e nt Num be r
01 M I-M P 12-20 00 -0 01-HTR00 01 A HTR10 00 1 Re plac e O il Pum p 15 00
= Fields to be entered
13
Prototype: Concept
3) Summarise by Cost Centre
Cost Centre Cost Element Total Costs

MCP001 404000 $60.400,00
MCP001 601600 $7.500,00
MCP001 Cost Element $67.900,00
Cost Centre Cost Element $67.900,00
Protype: SEM-BPS
14
Prototype: Planning Workbench
Prototype: Selection of Planning Folder
15
Prototype: Planning Screen
16
17
Maintenance Cost Planning: Current Status and Future
Planning
Development Request being evaluated by GBU
Estimate of time and resources
Approval process
Identify charter customers
Write Functional and Technical Specfications
Develop and deliver solution
Maintenance Solutions for the Mining Industry
Activities to date
Current Activities
Î Future/Planned Activities
18
Updating existing scenarios
Add more scenarios
Maintenance KPIs
Portals
Mobile Maintenance
RCM
Other
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Maintenance

Dean Fitt SAP AG

 SAP AG 2002, Title of Presentation, Speaker Name 2

Strategic Enterprise Business Intelligence & Workforce Planning &

Mining & Primary Asset Lifecycle

Sales & Distribution Sales Outbound Logistics Assay Handling Invoicing

 SAP AG 2002, Title of Presentation, Speaker Name 3

Scope of Best Practices for mySAP Mining (4.6C)

Concentrate Sales Concentrate Blending Concentrate

 SAP AG 2002, Title of Presentation, Speaker Name 4

 SAP AG 2002, Title of Presentation, Speaker Name 5

Unplanned Maintenance: Work Order Overview

1 Notification • Technical object • Date

2 Planning • Operations • Material

3 Scheduling • Order release • Capacity leveling

4 Execution • Planned/unplanned material withdrawal

5 Completion • Time confirmation • Order settlement

 SAP AG 2002, Title of Presentation, Speaker Name 6

 SAP AG 2002, Title of Presentation, Speaker Name 7

Refurbishment Process for Major Components

Articulated Dump Truck

 SAP AG 2002, Title of Presentation, Speaker Name 8

Order No 2: Refurbishment Order Goods Issue of

 SAP AG 2002, Title of Presentation, Speaker Name 9

Post to stock with

 SAP AG 2002, Title of Presentation, Speaker Name 10

 SAP AG 2002, Title of Presentation, Speaker Name 11

WCM: Maintenance Processes

Create Plan Release Confirm Complete

 SAP AG 2002, Title of Presentation, Speaker Name 12

Production capacity requirements are generated from planned and

 SAP AG 2002, Title of Presentation, Speaker Name 13

Capacity Planning: Maintenance Requirement

Maintenance capacity requirements are generated from Maintenance

 SAP AG 2002, Title of Presentation, Speaker Name 14

The planner can see the impact of the Maintenance

 SAP AG 2002, Title of Presentation, Speaker Name 15

Maintenance Solutions for the Mining Industry

 SAP AG 2002, Title of Presentation, Speaker Name 16

In core SAP R/3, we cannot effectively link maintenance

 SAP AG 2002, Title of Presentation, Speaker Name 17

Maintenance Cost Planning: History

 Long standing requirement from mining customers

 One of the top requirements from IACM

 High Level Requirements received

 Investigated various options

 SEM-BPS identified as suitable tool

 Prototype developed in SEM-BPS

 Presented prototype at April IACM meeting

 Workshops held in Melbourne and Johannesburg

 Development Request received beginning June

 SAP AG 2002, Title of Presentation, Speaker Name 18

 Based on SAP SEM-BPS

 SAP AG 2002, Title of Presentation, Speaker Name 19

Prototype: SAP SEM Strategic Enterprise Management

Strategy Management Performance Business Consolidation Business Planning Stakeholder

 SAP AG 2002, Title of Presentation, Speaker Name 20

SAPGUI Excel-In-Place Excel Client

Planning Folder ALV Grid

 SAP AG 2002, Title of Presentation, Speaker Name 21

Prototype: Reporting and Analysis

SAP SEM Pefomance SAP SEM Management Cockpit

SAP BW-Alert Reporting SAP BW-Excel SAP BW-Web Reporting

Long standing requirement from mining customers

One of the top requirements from IACM

High Level Requirements received

Investigated various options

SEM-BPS identified as suitable tool

Prototype developed in SEM-BPS

Presented prototype at April IACM meeting

Workshops held in Melbourne and Johannesburg

Development Request received beginning June

Based on SAP SEM-BPS

Estimate of time and resources

Identify charter customers

Write Functional and Technical Specfications

Develop and deliver solution

Updating existing scenarios

Add more scenarios