Integrated Mining Command & Control Centre
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Integrated Mining Command and Control Centre – IMCCC
CMC's mining group began its pioneering delivery of world class IT solutions to national and international mining companies in 1987. Over the last 25+ years it has designed, deployed and supported IT and automation solutions spanning across the mining value chain for its esteemed customers. 
 

Integrated Mining Command and Control Centre(IMCCC) solution provides a collaborative environment, across the mining value chain and covering all activities such as exploration, mine operations, ore processing, and transportation and ore dispatch / ore exports. The solution uses an integrated automation system to minimise the complexities of recording, tracking,reconciling and planning through the entire process of mining, processing and dispatching of ore and waste.

 

The IT components of the solution are designed to gather, manage, analyse information and enable the key decision makers to access the information required to make short term decisions and improve long term strategies. The solution supports business intelligence and corporate reporting tools to develop standard Key Performance Indicator (KPI) reports. The KPIs have capabilities listed to permit rapid identification of cause and effect. The business process data is integrated in a central location and can be analysed for various KPIs that the client wishes to measure.

 
IMCCC Functional Areas
 
Mining operations control
 
IMCCC consolidates and integrates the data required for KPIs from existing and proposed systems at various stages of the mining value chain, to boost production, cut costs and save energy, while ensuring maximum safety for personnel, machinery, materials and the mine, also conserving natural resources such as water and air. IMCCC optimises the entire process across the mine’s value chain from pit-to-port, i.e. from excavation to export. On consolidation, the data is available on a central repository for reporting.
 
The system integrates all existing & new systems across the mining value chain.  
 
Integrated Mining Command and Control Centre
 
 
 
Key Modules 
Our solution has two major components
 
1) Real-time monitoring & Optimisation of mining operations
To bridge the automation gap in the mining operations area, we deployed the following systems involving software, hardware and communication components for real-time monitoring and optimisation of the mining operations:
  • GPS-based truck dispatch system (DYNAMINE)
  • Real-time Equipment Health Monitoring System
  • Dedicated high speed radio network across the entire mining area
  • Flow metre to get real time fuel consumption
  • Weighment system to get real time production statistics
2) Integration & Dashboard subsystems integration
a) We designed and developed a real time integration system, encompassing all existing applications including SAP as well as new applications like the truck dispatch system. This integrated system involves the design and development of an integration framework to enable the real time exchange of data between the IMCCC and various standalone applications and systems as given below:
  • Integration with the barge monitoring and optimisation system
  • Integration with the RFID and SAP system for real time data of ore transport by road from mines to plants, jetties and stockyards
  • Integration with the SCADA system at the iron ore processing plants, both dry and wet
  • Integration with Dynamine
  • Integration with SAP to obtain maintenance and costing data of the mining, plant and transportation operations
  • Integration with SAP for automatic pushing of key mining and plant production data in real-time to SAP from Dynamine and the plant SCADA system
b) We designed and developed control room dashboards for monitoring key KPIs of the entire mining value chain in an integrated manner, using the SAP business objects platform.
  • Dashboards for key KPIs were designed and integrated with the data store. Data store receives live data in real time through the integration framework
  • These dashboards are hosted in a command and control centre where mining and maintenance engineers monitor the KPIs and take further action based on live data.
  • Alerts dispatched on email & SMS to key operation and management team members

 

In our experience, customers experience greater control over the entire mining value chain within three months of deployment. This helps in increasing production, reducing costs, improving safety and access to business intelligence capabilities.
 
Real-time HEMM fleet monitoring and control
  • Real-time display of the entire mining operations on a mine map, making all critical parameters available at the click of a button
  • Empowering supervisors with real-time data of critical KPIs to enable them to take informed decisions
Dynamic allocation of shovel-dump truck combination
  • Increased productivity of both equipment and human resources
  • Reduction in shovel idling and dump truck queue time
  • Dynamic allocation of trucks to shovels at each cycle time to maximise productivity under user definedblend and other constraints
HEMM – health monitoring
  • Online monitoring of vital health parameters of equipment and generation of warnings, breakdown analysis and preventive maintenance schedules
  • Optimal utilisation of equipment and prevention of pre-mature equipment breakdowns
  • Reduction of emergency maintenance and help in adopting a condition-based maintenance methodology
Real-time reporting, operator allocation and performance
  • Online reports relating to production, performance, health, utilisation, availability, safety violations, operational warnings, crew performance and incentives thereby helping to increase shift working hours
  • Correct measurement of equipment idle time
  • Automatic allocation, thereby reducing time lost in shift start
  • Help in managing productivity techniques like hot seat change
Safety management
  • Prevention of inadvertent entry of HEMM in prohibited areas by generating alerts to both operator and the control centre
  • Enhanced safety by providing over-speeding alerts
  • Immediate feedback to equipment operators reinforces desired behaviour in operation
Road logistics
  • Increased visibility across the entire road logistics chain improves efficiency and identifies potential choke points
  • Route-wise real-time cycle time KPI analysis helps logistics team plan for alternative scenarios to achieve higher efficiencies
River fleet logistics
  • Real-time tracking and optimisation of barges improves operational planning and increases bargeutilisation
  • Real-time view of floating cargo (quantity and grade), availability and utilisation of jetties, barges and un-loaders and dynamic allocation of barges while respecting user and nature-driven constraints helps barge fleet supervisors improve productivity
  • Real-time monitoring of critical health parameters of barge engines increases barge availability and prevents their pre-mature failure
Process Plant Monitoring and Control
  • Tracking of key plant KPIs like energy consumption, water consumption, plant recovery, etc.
  • Optimal utilisation of equipment and prevention of pre-mature equipment breakdowns
Prospecting Operations Management
  • Monitoring prospecting operations against target
Ore Inventory Management
  • Integrated view of mine operations, along with integration of data across functions and systems, helps mine management monitor the movement of ore inventory
 
 
  • Dashboards: SAP BO / Pentaho
  • RDBMS : Oracle 11g
IMCC Technologies
 

Indicative Client List

  • Sesa Goa Limited – A Vedanta Group Company
 
IMCCC has the following capabilities which sets it apart from the rest
  • State-of-the-art design
  • Componentised design for faster customisation and enhancements
  • Scalable architecture delivering same performance and responses
  • Comprehensive functionality with intelligence and automation
  • Open systems interface for devices and third party systems
  • Operations dashboard and consoles for proactive decision making
  • MIS dashboards for strategic decision making
  • Adhoc report generation