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Iot Opportunities for Industry 4.0

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Iot Opportunities for Industry 4.0 EMPOWER YOUR ANALYTICS WITH OPERATIONAL DATA 2019 OSISOFT MUMBAI SEMINAR IoT opportunities for industry 4.0 Neelesh Chawda 14th October, 2019 Head Milling Excellence, HZL one vision . one vedanta . Industry opportunities and challenges one vision . one vedanta . Opportunity to scale up Mining Autonomous Vehicles Estimated worldwide 88,000 110Mn uber users across the mining equipment in use world Data volume are up 500 folds Handles 3Mn drivers around over past 10 years different parts and timelines of world Only 20% of network capacity With 110Mn uber users, only industry need in 2020 exist today caters 69% of US market 62% of workforce think having Completely mobile access to application helps App and IoT to do better job based operations Working mine or cluster might be Operates in 80 countries and next door or halfway across 400 cities across globe world one vision . one vedanta . Industry challenges We are mature and proactive org, but We want to be data-driven, but… We need to cut costs, but… UNNECESSARY EXCESSIVE Loss time are of the UNPLANNED MAINTENANCE don’t know which cuts DOWNTIME COST 89% not time based 85% effort push us over our risk tolerance is in gathering and aggregating the data Operational Silos Average in a week Less Innovation and working investment as compared to other 40% hours are lost Reactive or Break / Fix due to inefficient communication sectors Maintenance Culture Organizational Working hazards and Care for Environment and Knowledge Loss mitigation of safety risks natural resources Data Not Accessible or Proactively Analyzed We know asset failure is often IT & OT data sources are diverse We don’t know where to cut random; however, we don’t have a and siloed, resulting in limited or where the point of diminishing better set of diagnostic tools visibility across an enterprise returns resides LOST LOWER REVENUE PROFITABILITY PEOPLE PROCESS TECHNOLOGY one vision . one vedanta . *Source: Nowlan and Heap study Hindustan Zinc Limited and usage of PI System capabilities one vision . one vedanta . World’s 2nd largest integrated Lead & Zinc mining operation, 4th largest smelting operations and 9th largest silver producer scattered in 8 different geographical location Chanderiya Smelting Complex Rampura Agucha Mine Pyrometallurgical Lead Zinc Smelter: 105,000 Reserves & Resources : 96.5 Mt tpa Zinc and 35,000 tpa Lead Ore Production Capacity : 6.15 Mtpa Hydrometallurgical Zinc Smelter: 420,000 tpa Zinc Kayad Mine AusmeltTM Lead Smelter: 50,000 tpa Lead Reserves & Resources : 8.3 Mt Captive Power Plant: 234MW Ore Production Capacity : 1.2 Mtpa Dariba Smelting Complex Sindesar Khurd Mine Hydrometallurgical Zinc Reserves & Resources : 126 Mt Smelter: 220,000 tpa Zinc Ore Production Capacity : 6.0 Mtpa Lead Smelter: 100,000 tpa Lead Captive Power Plant: 160MW Rajpura Dariba Mine Zinc Smelter Debari Reserves & Resources : 60 Mt Hydrometallurgical Zinc Ore Production Capacity : 1.08 Mtpa Smelter: 88,000 tpa Zinc Zawar Mining Complex Pantnagar & Haridwar Reserves & Resources : 100.5 Mt Processing & Refining of Ore Production Capacity : 4.0 Mtpa Zinc, Lead & Silver Wind Power Generation Capacity of around 274 MW one vision . one vedanta . 6 Data Sources and working platforms one vision . one vedanta . 7 Applicability of OSIsoft PI System on different business levers Efficiency People • Single source of truth • Data based live feed discussions • Quicker response • Manpower engagement to value • Automated shift reports added work and future prospects • Event based email notifications • Performance monitoring & training • Easy to communicate with various identification DCS and ERP platforms to have end • Analytical based capability to end business visibility measurement and appraisals • Mobility capability Asset Cost • Data & Analysis Based RCA • Real Time Consumables tracking • Model based predictive maintenance • Cost control – Real Time and material planning • Consumables optimization • Improved safety and reduction in • Building cost consciousness to unscheduled breakdown bottom most layer one vision . one vedanta . 8 Real time monitoring – Soft Sensor capability Based on data history and dependent variable soft sensor can be developed ➢ For instruments not installed in process ➢ For continuous online calibration of existing instruments 9 one vision . one vedanta . Disclaimer - Numbers stated are for indication purpose and do not represent actual industry operations Real time monitoring – Material planning ➢ Crusher liner and screens replacements from panel data, physical inspections and time based to real time condition based monitoring ➢ Captures trends of replacement and enables to communicate with OEMs in better way for further opportunities ➢ Improved inventory planning 10 one vision . one vedanta . Disclaimer - Numbers stated are for indication purpose and do not represent actual industry operations Real time monitoring – Predictive maintenance planning ➢ Enabled to track comprehensive KPI and compare different assets ➢ Condition based sequencing of fleet for maintenance resulting in effective use of maintenance bay and improved productivity ➢ Historical data of asset health and maintenance helps in standardizing SOPs, SMPs & RCAs 11 one vision . one vedanta . Disclaimer - Numbers stated are for indication purpose and do not represent actual industry operations Real time monitoring – People improvement ➢ Tracking operators and people performance based on respective asset performance or shift performance ➢ Identifying training and mentoring needs of people to improve their skill sets and productivity ➢ Data and analytical based appraisal system 12 one vision . one vedanta . Disclaimer - Numbers stated are for indication purpose and do not represent actual industry operations Real time monitoring – Making APCs smarter ➢ Using advance analytics and history to develop, refine and improve process predictive models. ➢ Once required accuracy of model is achieved we intend to feed this model to APCs to up our productivity ➢ Planning to make APCs smarter not only for process control but for better asset health too 13 one vision . one vedanta . Disclaimer - Numbers stated are for indication purpose and do not represent actual industry operations Real time, customised dash boarding and reports generations through power Bi Average Ball mill power 1980kw Crusher output size p95 14 one vision . one vedanta . Disclaimer - Numbers stated are for indication purpose and do not represent actual industry operations Through digital transformation Industry can target benefits 5-10% 10-15% 85% 10-15% 10-15% Forecasting COP OEE Efficiency Productivity accuracy reduction improvement one vision . one vedanta . 15 Future expectations from OSIsoft PI System development one vision . one vedanta . Capabilities OSIsoft PI System should have Android, IOS and Notification counter windows based App development Easy arithmetic like avg, min, max enablement in PI Vision Pareto capability in SPC/SQC on PI Vision PI Vision one vision . one vedanta . Thanks one vision . one vedanta ..
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