Lonmin’s improved batch tracking and monitoring saves millions
MINING, MINERALS & METALS
Goals
- Allow for the build-up of materials for processing;
- Track the genealogy and content of materials;
- Track process variables and statistics;
- Provide electronic log sheets;
- Provide full production reporting facilities and
- Cater for full integration between the lab, the automation system and MES
Challenges
- Protect the intellectual property of the process
- Ensure system maintainability
- Cross-skilling between teams
- Ensure cost saving
- Short timelines and limited resources
Results
- Once-off cost saving of R300 million
- Saving of R20-R30 million by doing this project internally
- Batch tracking and batching of real-time information
- Standards ensured consistency, automation of PLC code generation, reusability of code/objects and ease of integration
- Fully-integrated “shop floor to top floor” architecture
Solutions & Products
- System Platform
- Historian
- Application Server
- TOP Server

Implementation
“When we found ourselves in the middle of a five-month strike during 2014, we sought ways to improve our processes and efficiencies,” says Gawie Reyneke, Lonmin’s MES and MRM Manager. “So we decided to focus on an in-house implementation that would result in a new production process and management system that was innovative from top to bottom and that would save us millions.”
Some of the reasons why Lonmin decided to do the development themselves included:
- IP protection – the company needed to protect the intellectual property that contributed to the new process and outsourcing the project could compromise this;
- Maintainability and cross-skilling – the two teams representing the Platinum Metal Refinery and the Marikana operation were brought together in order to increase knowledge of the system and its maintainability
- Reduce development and implementation costs – since operations had all but stopped, keeping costs as low as possible was a high priority.