Presentation by Peter Bates, Manager, IT & Business Systems, Xstrata Copper at the Australian CIO Summit 2012: The New Black: Integrating Middle Tier Tools to Leverage the Benefits of Each System

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3. Introduction
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4. Integrating Middle Tier Tools to
Optimise the business, reduce downtime &
maximise plant productivity
Increase visibility & transparency accross the
entire Supply Chain
Advanced planning and scheduling to reduce
costs and boost profits

6. Q=vÉ~êë=^Öç=KKKKK=qÜÉ=bñéÉÅí~íáçå
Integrated pit-to-port System that knew
•What to produce in all processes, and what was produced
•What ore grades required, & geological mappings
•What materials required (fuel, grinding media, explosives)
•What rail requirements for inbound/outbound logistics
•When to schedule ships (and type)
•What maintenance windows required
•What alternate strategies (incl safety stocks) for outages
•What workforce required for each shift (incl FIFO logistics)

7. 4 Years Ago ..... The Reality
Spreadsheets
and systems in disrepair
•Data entry errors
•Data not validated
•Data manipulated
No Truth

8. Spreadsheets
• Manual process
• Uncontrolled – audit difficult
• Many spreadsheets
• Error prone

9. Operation Management
al System
Reports
#1
Operation
al System Management
#2 Reports
Management
Spreadsheet Reports
Executive /
Operation Management Senior Management
al System Reports Team
#3
Spreadsheet
Source
Spreadsheet
Spreadsheet
Source Management
Reports Spreadsheet
Spreadsheet
Operational
Layer
Spreadsheet

10. Various
Process
MES LIMS
Data
System
Operations
Transaction Layer PI
Stock Metal
Management Balancing
Cathode
Mine Planning
Production
Decision Support
Forecasting,
Logistics Planning
Planning & Concentrator &
Rail, Road & Port
Smelter Planning
Scheduling S&OP
Commercial Various
Ellipse Aramis
Transaction Layer systems
Management Presentation & Balanced Scorecard
Reporting Layer Reports
Hyperion

11. The Solution ........
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13. Excel
Analysis Secondary Operational Ellipse
and Upload Data Entry reporting
PI
OSI PI
Process
Book
SCADA
LIMS Production
Reports
PIMS
Process Downtime
Primary Visualisation Capture Downtime
Data Entry Reports

16. Downtime
Putting CONTEXT into
Production Reporting
Critical for
• Debottlenecking Processes
• Real-time Asset Performance
Real-
• Data Capture for FMECA*
• Eliminating Manual Recording
• Raising Work Notifications
FMECA:
Failure Mode & Effects Criticality Analysis
16

17. Production Report

19. Easier identification of key
information
◦ Enabled to be viewed on
compliant report technologies
(e.g. Microsoft SQL Server Reporting
Services Reports)
◦ HTML editing
Text fields support multiple
lines
Linking to external files and
URLs
◦ E.g. attach photos and external
reports to a shift log.
Linking records to equipment,
people, and/or material.
◦ E.g. link a safety incident
record to the equipment that
caused it.
More Filtering options

20. Raw Feed Bin 354 needs to be
cleaned out

22. SolveIT Architecture
Optimised
Various Integrated
View Configuration &
Data Time Period
Sources Configuration
SolveIT
Multiple Software
Sites Copper Refinery
Supply Chain Forecast
Planning &
Dashboard & Modelling
Reports Logistics /Port
stockpile
modelling,
shipping
Alerts planning
Copper
Mine Zinc Smelter & Copper
Planning Lead Smelter Concentrator Emissions Concentrator
S&OP Planning Planning Planning Planning

23. Copper Mine Planning
Short/Long Term
Copper Processing NT
APS
S&OP Supply Chain
Management
Zinc/Lead APS
Supply Chain
Management
Truck/Rail/Ship
Planning &
Scheduling
Stock Forecasts
Anode/Cathode
Forecast,
Planning, and
Scheduling
System

24. Global Optimisation: Local
What’s best for the Optimisation:
entire business What’s best for a
business silo

25. Mine Mine Rail Port Port
Processing
Planning Stockpile Logistics Stockpile Logistics
Ore Mine Rail Port Port
Mine Planning Processing Stockpile Logistics Stockpile Logistics
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26. Planning, Scheduling & Optimisation
- What to Produce enterprise-wide

27. Planning, Scheduling & Optimisation
- What ore grades, where to find

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•What to produce in all processes, and what was produced
•What ore grades required, & geological mappings
•What materials required (fuel, grinding media, explosives)
•What rail requirements for inbound/outbound logistics
•When to schedule ships (and type)
•What maintenance windows required
•What alternate strategies (incl safety stocks) for outages
•What workforce required for each shift (incl FIFO logistics)
Visible to everyone across the entire enterprise
Real time information
Optimised for any condition, delay or outage
Scenario capability to plan for any event

31. Future (Forecast)
Time Domain Ellipse
Present & Past (Historical)
Weighbridge
Pi
LIMS Barcode or
Historian RFID, other

32. Process Various
Data MES LIMS
Systems
Operations
Transaction Layer PI
Stock Metal
Management Ampla Balancing
Cathode
Mine Planning Production
Logistics to Port
Forecasting, / Customer
Planning &
Concentrator &
Scheduling Smelter Planning
S&OP
Commercial Various
Ellipse Aramis
Transaction Layer systems
Management Presentation & Balanced Scorecard
Reporting Layer Hyperion
Reports
CONFIDENTIAL – Property of SolveIT Software © 2011

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Mines Logistics Ports
Local Global
Optimisation: Optimisation:
What’s best for What’s best for the
an operating silo entire supply chain
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