Tag Archives: Mining & Metals

 

By integrating their Management Operating Systems (MOS) with AI and IoT, mining and metals companies can significantly enhance their operational capabilities, leading to better asset management, increased productivity, and ultimately, improved financial performance.

Utilizing IoT devices, such as sensors and connected equipment, to continuously collect data on various aspects of their operations, including equipment performance, environmental conditions, and production metrics, this real-time data is fed into the MOS, providing a comprehensive and up-to-date view of operations. The collected data is then analyzed by AI algorithms within the MOS to generate insights, identify patterns, and predict outcomes, allowing for proactive management of assets and operations, such as predicting equipment failures or optimizing production schedules.

A key aspect of any MOS is to assist management in decision making. Integrating AI with MOS enables real-time decision support, where AI provides recommendations or automates decision-making processes based on the analysis of IoT data. This helps managers make more informed decisions quickly, improving responsiveness to changing conditions. Additionally, AI allows the MOS to simulate different operational scenarios and predict their outcomes. This capability helps managers evaluate the potential impact of different decisions before implementing them, reducing risks and optimizing outcomes.

By focusing on operational efficiency, AI models integrated into the MOS can optimize processes in real-time by adjusting operational parameters based on current conditions and historical data, leading to improvements in ore and metal recovery, energy efficiency, and overall productivity. AI can also be used to analyze data on resource usage and availability, helping the MOS to optimize the allocation of resources such as labor, equipment, and materials, leading to cost savings and improved operational efficiency.

When approaching enterprise asset management and predictive maintenance models, integrating AI and IoT with the MOS, companies can enhance their predictive maintenance capabilities. AI algorithms analyze sensor data from IoT devices to predict when maintenance is needed, helping to prevent unexpected equipment failures and reduce downtime. This assists the MOS to automatically schedule maintenance activities based on AI predictions, ensuring that maintenance is performed only when necessary and that it is coordinated with other operational activities.

The use IoT and AI integration helps the MOS to optimize inventory levels by predicting demand for spare parts and materials based on operational data, thus reducing inventory costs and ensuring that critical components are available when needed. By having AI analyze data across the supply chain, assisting the MOS to optimize logistics, reduce lead times, and minimize costs associated with the procurement and transportation of materials.

Integrating Management Operating Systems with AI and IoT in the mining and metals industry offers substantial benefits, but it also comes with several challenges and potential pitfalls.

USC partners with your organization and coaches your people to significantly impact performance outcomes and accelerate Operational Excellence

For more than 55 years, USC has been working with clients to address the challenges and avoid the pitfalls when developing, enhancing and deploying their management operating systems.

As technology enablers, like AI and IoT, are deployed, we help clients to address the challenges through careful planning and a strong focus on change management, including employee involvement.  By proactively identifying and mitigating the pitfalls, mining and metal companies can successfully integrate AI and IoT with their MOS, unlocking the full potential of these technologies for improved asset management and operational efficiency.

Integrating AI and IoT into MOS often requires close coordination across different departments, such as IT, operations, and maintenance. Misalignment or lack of communication between these departments can lead to project delays and failures. The complexity of integrating AI and IoT, projects can often experience timeline and budget overruns. Effective project management is critical to keep the implementation on track and within budget.

Mining and metal operations often have data scattered across different systems and departments. Integrating this data into a unified MOS that can effectively leverage AI and IoT is challenging, particularly if the data is stored in incompatible formats or is not standardized. AI systems require high-quality, accurate data to function effectively. Inconsistent, incomplete, or inaccurate data can lead to poor AI performance, resulting in unreliable predictions or insights. Ensuring that data from IoT devices is processed in real-time is crucial for effective AI-driven decision-making. However, high latency in data transmission or processing can lead to delays, reducing the effectiveness of AI in making timely decisions.

Many companies often face a skills gap when it comes to AI, IoT, and data analytics. There may be a shortage of in-house expertise required to manage and maintain these advanced technologies effectively, so having a partner can assist in compressing the time it normally takes cleanse data and align MOS processes. Employees accustomed to traditional methods may resist adopting new technologies, especially if they perceive AI and IoT as threatening their jobs or making their roles redundant. Effective change management and training programs are essential to address this issue.

Companies that have integrated their Management Operating Systems with AI and IoT are experiencing several quantifiable benefits across various aspects of their operations. These benefits are often measurable in terms of improved safety (30-50% reduction in safety incidents), cost savings (10-40% reduction in maintenance costs), and an increased productivity (5-15% increase in productivity and 10-20% improvement in operating efficiency), just to name a few. By leveraging these technologies effectively, mining and metal companies can achieve substantial improvements across their entire value chain.

USC helps you tackle key challenges

Do you want to understand how a MOS can integrate your mine and operational planning, while helping you to safely increase performance site wide? Contact us today.

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A robust MOS is vital for mining and metal companies to navigate the challenges of today’s market.

Management operating systems (MOS) are making significant impacts to performance goals and outcomes for mining and metals companies by providing a structured and systematic approach to managing the business across the value chain. Companies have a strong need for robust MOS in today’s market to ensure safety and compliance, improve efficiency, and achieve sustainable growth, given the safety of workers is a top priority across the mining industry;  the global demand for minerals and resources is rising, leading to increased competition; mining operations are inherently complex; the industry is facing significant cost pressures from fluctuating commodity prices and rising operational costs; and the adoption of new technologies requires an integrated approach to managing operations.

Performance is improved by providing a structured framework for planning, monitoring, and controlling operations. MOS can help through:

  1. Safety and Compliance – ensuring that safety protocols and regulatory compliance are integrated into daily operations, while minimizing the risk of accidents and legal issues, promoting a safer working environment.
  2. Enhanced Planning and Scheduling – creating detailed and realistic operational plans and schedules, ensuring that resources are allocated efficiently and that production targets are met without unnecessary delays. Potential bottlenecks can be identified and addressed during the planning process – “Planned work is safer and more productive than unplanned work.”
  3. Real-Time Monitoring and Control – tracking operations in real time, allowing for quick in identification and in-shift resolution of issues, while reducing downtime and safeguarding that operations run smoothly.
  4. Improved Communication and Coordination – standardizing processes and providing clear protocols, MOS enhances communication and coordination among different departments and teams, leading to more cohesive and efficient operations.
  5. Data-Driven Decision Making – providing and analyzing comprehensive data on various aspects of the operations to identify trends, inefficiencies, and opportunities for improvement and leading to more informed decision-making.
  6. Cost Control and Efficiency – optimizing resource use and reducing waste, while aiding in cost control and improving operational efficiency.

Supporting mining and metal companies to stay competitive and adapt to changing market conditions, MOS fosters a culture of continuous improvement by regularly reviewing processes, identifying areas for improvement, and implementing changes.

MOS in mining and metal operations are significantly enhanced by today’s technological advancements. By leveraging these advancements, MOS becomes more robust, responsive, and efficient. This not only enhances operational performance but also ensures better safety, sustainability, and profitability.

USC partners with your organization and coaches your people to significantly impact performance outcomes and accelerate Operational Excellence

USC brings a tailored, structured, and disciplined methodology, along with a range of tools and techniques we apply collaboratively with client’s personnel. Whatever your challenge, we are the people who work with our clients to find full potential and unlock the hidden value.

USC identifies waste, redundancies, and ineffective processes, and then rapidly recover the prioritized opportunities, and convert them to improvements in performance and operating profit. Our consultants achieve this by improving the skills sets of all levels of the client’s management and employees.

Our people embed with client internal teams to develop, enhance, prototype, validate and implement management operating system (MOS) element improvements to drive, sustain and perpetuate change in how the business budgets, plans, schedules, assigns work, executes, follow-up, reports, analyzes and improves. In short, USC implements measurable, sustainable changes that drive operational and financial improvements.

Our Management Operating System (MOS) Essentials Framework is designed to be pragmatic rather than conceptual – thereby leading to accurate, practical decisions about your operations and outcome aspirations. The key, that many miss, is the linkage process execution with management behaviors. MOS is about “managing differently” using visibly deployed management and supervisory behaviors. Consistent execution of the right behaviors at the right time creates certainty in the workplace, driving performance improvement and sustainable new ways of working.

MOS Process and Behaviors

Client performance goals and outcomes are realized through:

USC Helps You Tackle Key Challenges

Do you want to understand how a MOS can integrate you mine and operational planning, while helping you to safely increase performance site wide?

Want to find out more about how USC can help you uncover the hidden value loitering in your operations?

For more information, let’s talk it through with a no obligation meeting with one of our executive team members. Email info@usccg.com to arrange a call.

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Mining and metals companies are implementing a range of strategies to enhance asset management and equipment reliability.

In today’s market, many senior executives leading natural resource companies hesitate in making additional capital investment and instead focus on what can be done to squeeze higher performance out of current assets. Consequently, companies are increasingly looking for ways to improve performance and returns with existing infrastructure.

The key approach to this challenge lies in upgrading and improving asset management capabilities. Many organizations have failed to deploy optimal asset management practices. This is surprising given that asset spend frequently represents 30% to 50% of the overall operating expenses. Shifting to a best-in-class asset management program will consistently deliver improved plant or equipment performance, lower operating costs, extend asset life, and generate a higher return on capital. Most recently, companies have sought to implement a range of strategies such as:

  1. Implementing Asset Management Systems: Utilizing robust asset management systems to track equipment performance, maintenance history, and lifecycle costs, allowing for better decision-making regarding repairs, replacements, and upgrades. Digital technologies like IoT sensors, AI-driven analytics, and automation further optimize asset management.
  2. Enhancing Maintenance Practices: Implementing proactive maintenance strategies like conditioned-based monitoring and reliability-centered maintenance to address issues before they cause failures. Utilizing data-driven insights, mining companies can optimize “time on tools” by identifying patterns and trends in equipment usage, maintenance needs, and performance. This allows for more precise scheduling of maintenance tasks, reducing downtime and maximizing the time equipment is operational.
  3. Investing in Training: Providing comprehensive training programs for front-line management, maintenance and operations personnel to ensure equipment is used and serviced properly, reducing the likelihood of breakdowns due to human error and that access to equipment is available. Training personnel to utilize data-driven insights enables management to make informed decisions impacting “time on tools” and leading to improved equipment utilization and overall operational performance.
  4. Improving Supply Chain Management: Ensuring timely access to quality spare parts and materials to minimize downtime caused by equipment breakdowns and repairs. Some are adopting blockchain for transparent supply chain management and better tracking of assets throughout their lifecycle.

The level of performance improvement companies can realize by implementing key strategies such as enhancing proactive maintenance practices, investing in training to improve skills and capabilities, improving supply chain management, and leveraging digital technologies and data-driven insights varies depending upon factors like current operational efficiency, the scale of implementation, and industry conditions. However, many can expect significant improvements in:

  1. Safety: Proper training programs and proactive maintenance strategies contribute to a safe work environment by reducing risk of accidents and equipment failures.
  2. Productivity: Proactive maintenance and digital technologies can reduce downtime, increase equipment availability, and optimize process execution, leading to higher productivity levels.
  3. Cost Reduction: Efficient equipment usage and maintenance practices can lower operational costs by minimizing unplanned downtime, reducing repair and replacement expenses, and optimizing resource utilization.
  4. Quality: Improving the essential management skills and work place practices result improve the quality of maintenance execution.

Overall, these strategies can result in substantial performance improvements, enhancing competitiveness and profitability for mining and metals companies.

USC Consulting Group partners with your organization and coaches your people to significantly impact performance outcomes and accelerate Asset Management and Reliability Excellence.

USC’s experience helping clients to shift asset performance by transforming and optimizing asset management capabilities and processes has repeatedly demonstrated the need to focus on the key levers and enablers to asset management and reliability excellence. Our asset management framework is designed to be pragmatic rather than conceptual, thereby leading to accurate, practical decisions about a client’s assets and aspirational outcomes.

The primary goal of USC’s asset management framework is to help our clients to implement and execute of a robust set of integrated processes and tools to manage and maintain their operational assets at the targeted service levels while optimizing life-cycle costs and asset life. This is accomplished by recognizing the needs to:

Our asset management and reliability framework helps clients identify an organization’s asset management maturity level and the areas and gaps that need to be addressed, by evaluating their strategic, tactical and operational levers and the enablers that comprise each.

Asset Management Triangle

Strategic (Lifecycle Management): A tailored maintenance program for each piece of equipment translates overall strategic objectives into executable plans for equipment upkeep. Our framework helps to structure and prioritize critical assets while defining a baseline operational ‘plan of action’ by determining strategies for maintaining equipment based on analysis of equipment capabilities, required performance levels, failure frequencies, and cost objectives. Optimal maintenance strategies are frequently a blend of preventative, predictive, operator-maintained, and run-to-fail options.

Tactical (Business Processes): Business processes bridge the gaps between the initial, ideal plan and the reality of ‘day-to-day’ operations, so the maintenance and reliability organization can make adjustments. Historically, many maintenance organizations have been poor utilizers of labor resources that result in low “time on tools” and excessive delays in repairing down or poor performing equipment.

Operational (Enablers): Enablers help to identify needed support to manage assets throughout their lifecycle in alignment with organizational aspirations. Leading asset management teams have also made changes in their organization structures and management practices to foster more action-oriented leadership that focuses on operational excellence, which usually requires a culture shift that must be relentlessly supported by the leadership team over the long-term. A heavy emphasis on management behaviors and company culture can help organizations make this difficult transition.

USC Helps You Tackle Key Challenges

Do you want to understand how prepared your company is to drive needed asset performance and reliability improvements and what the key focus areas that will contribute to lower operating costs?

Want to find out more about how USC can help you uncover the hidden value lurking in asset portfolio?

For more information, let’s talk it through with a no obligation video conference call or a meeting with one of our executive team. Email info@usccg.com to arrange a call.

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