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Enterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum
Thursday, June 19, 2008Thursday, June 19, 2008
EA practitioners conference - June 2008
Presented by Johan van TonderManager: Information Management Anglo Platinum
- 2 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Agenda for discussionAgenda for discussion
1. Understanding the business objectives of an Industrial IT program
2. Key considerations across the EA stack influencing the design
3. The importance of an effective approach to architecture
4. The IIT applications and technology architecture at Anglo Platinum
5. Key functional MES requirements for the minerals processing industry
- 3 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
An Industrial IT strategy focuses on Integrated Automation and Access to Information to support Decision Making. An Industrial IT strategy focuses on Integrated Automation and Access to Information to support Decision Making.
1. Metallurgical processes are continuous and highly automated. Effective control depends on a constant stream of high quality data.
2. Effective management of large integrated metallurgical complexes requires managers at all levels to coordinate their efforts.
3. A sustainable approach to Operational Performance Monitoring requires all levels of management to work from the same set of reliable information.
4. This enables operational effectiveness and efficiency targets to be agreed, to maximise business value.
5. Often attempts at metrics based management falter because the data gathering process is unsustainable.
6. Globally, systems used by Commercial and Industrial IT are converging
- 4 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
The road to Business and Operational Intelligence cannot be walked in a day… Will your design stand the test of time?
Q208 2009
‘As-Is’
H208 2010 2011
Atedf
‘To-Be’
Past
Ente
rpris
e ar
chite
ctur
eO
rgan
izat
iona
lch
ange
Smelter deploymentConcentrator deployment Refineries deployment
Work completed Current focus Longer term outcomes
Prod
uct
deve
lopm
ent
Agreed standards for all layers of EA for
IIT
Interim release for connectors
Main release: data contextualisation, multiple models &
templatesContracted
operational support
Refineries uses information from
automated sources
Agreed portal strategy in production
Smelter A uses updated reports
IIT plans incorporates
PLC roadmap
Smalter B uses updated reports
Agreed information
architecture for Smelters
Product is the best in MMM
Abnormal situation
management uses
competency centre
Production scheduling
active at refinery
Feed blend optimisation
active Enable asset
optimisation on MES ERP base
Global roll-out
Implemented PI platform for Smelter A
Agreed the design and roles
Phase 1 implemented for
furnaces
Phase 1 implemented for
milling
Concentrator dashboard in Excel, mostly manual data
capturing
Agreed conceptual
MES architecture
Phase 1 supported by management
Cross functional team lead the IIT
program
Competency centre operational
Agreed design for operational
support of IIT First plant uses automated dashboard
Phase 1 functionality across all
Concentrators
Agreed functionality for
product replacement
Agreed functional roadmap for IIT
deployment
All refinery data sources
in MESPilot uses MES
informationAgreed information
strategy
- 5 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Agenda for discussionAgenda for discussion
1. Understanding the business objectives of an Industrial IT program
2. Key considerations across the EA stack influencing the design
3. The importance of an effective approach to architecture
4. The IIT applications and technology architecture at Anglo Platinum
5. Key functional MES requirements for the minerals processing industry
- 6 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Business process considerations in the Industrial IT worldBusiness process considerations in the Industrial IT world
Human driven processes
– People execute the process steps
Human machine interactions in processes
– People control the process
– Machines execute the process
Automated machine interactions– Machines control the process
– Machines execute the process
- 7 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Information needs in the Industrial IT worldInformation needs in the Industrial IT world
BRPM Sec Mill Feed Stability – Flowrate
QC AnalysisStrategic decisions
Decisions to control process execution– Geographically disparate management
structure
– Continuous operations
– Functional experts
High degrees of sophistication– Tendency towards “lights out” automation
– Metallurgical processes are multi-variant
– Automates and Artificial Intelligence
Need for expert analysis– Collaborative decision making
– Line execution
– Experts on call
RPMA Merensky Conc Primary Grind - passing 75um [%]QC Analysis
From 10/01/08 06:00 To 10/03/08 22:00 (58.47% of data valid)WARNING LIMIT VIOLATION
10/01/0825/01/08
09/02/0824/02/08
04/0310/03/08
Date / Time
X: 42.70 (40.00); Sigma: 7.13 (1.00); n: 1.
10
20
30
40
50
60
70
80
90
100
RPM
A M
eren
sky
Con
c Pr
imar
y G
rind
- pas
sing
75u
m
[%]
3436404446
Capability(Last Set)Cpl = .40Cpu = .15Cpk = .15
Control Limit ExceededPersistant warning limit exceededWarning limit exceededIn control dataMissing data
- 8 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Five key models enables a contextualized view of data without compromising integrity or flexibilityFive key models enables a contextualized view of data without compromising integrity or flexibility
Event model
Event 10
Object 101
Process 10
Event 20
Process 20
Product 102
Attribute 1
Attribute 2
Event 30
Object 301
Inventory model
Inventory 10
Asset 10
Product 102
Process 10
Inventory 20
Object 201
Object 202
Attribute 1
Attribute 2
Inventory 30
Object 301
Asset model
Asset 10
Object 101
Object 102
Asset 20
Object 201
Object 202
Attribute 1
Attribute 2
Asset 30
Object 301
Product model
Product 10
Product 101
Product 102
Product 20
Product 101
Product 202
Attribute 1
Attribute 2
Product 30
Object 301
Process model
Process 10
Object 101
Product102
Product 202
Process 20
Object 201
Object 202
Attribute 1
Product 202
Process 30
Object 301
Product context
Process context
Inventory context
Asset context
- 9 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Technology considerations in the Industrial IT worldTechnology considerations in the Industrial IT world
Often linked to physical plant assets
Safety is a big consideration
“Always on” technology
Speed of data processing
Remote location often implies poor connectivity
Historical context implies “many different standards”
- 10 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Agenda for discussionAgenda for discussion
1. Understanding the business objectives of an Industrial IT program
2. Key considerations across the EA stack influencing the design
3. The importance of an effective approach to architecture
4. The IIT applications and technology architecture at Anglo Platinum
5. Key functional MES requirements for the minerals processing industry
- 11 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Your operating model will deliver an architecture and resulting product, but is that what you intended?Your operating model will deliver an architecture and resulting product, but is that what you intended?
In 1884, Sarah Winchester, heiress to the Winchester Arms fortune, bought a 6-room house in Santa Clara while still under construction.
She promptly discarded the plan, and kept 22 carpenters full time employed for 36 years!
The house eventually had approximately 160 rooms, with some very unique features:
– 3 elevators
– 47 fireplaces
– Rooms around rooms
– Staircases leading to no-where
– Doors opening to blank walls
– Doors opening to steep drops to the lawn
This was a perfect match for the owner’s needs,
- but she was trying to confine ghosts! www.prairieghosts.com/winchester.html
- 12 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Operational Intelligence is s sub-set of a sound Information Management strategyOperational Intelligence is s sub-set of a sound Information Management strategy
Support AAplc in their pursuit of
global initiativeswithin the group
• Align with Group IM in support of AAplc shared service objectives in Finance, HR, Supply Chain and SHE
• Reduce the cost of commodity IT services in agreement with business
Supportinternal competency
developmentin pursuit of continuous
improvement• Develop internal competency in
the management of information
• Develop internal competency in enterprise architecture practices
• Pursue a deliberate talent management program
Deliver and support industrial information technology systemsin Anglo Platinum’s
operations• Support operational performance
monitoring by leveraging data contained in base systems
• Develop and support the enabling industrial technology infrastructure in Process division
• Agree an automation strategy in Mining
Enable easier access to
high quality informationacross all levels of management
• Follow a consistent methodology in deploying business projects aimed at delivering better information
• Provide leadership to an information management competency centre in Anglo Platinum, incorporating AAplc group initiatives
Supportthe implementation of sustainable improvements in business process effectiveness• Support business process standardization by applying enterprise
architecture principles in the modelling of business processes• Develop and implement a business process management methodology
capable of supporting controlled changes to established practices• Develop a business process training methodology
Manage expectations through improved relationship managementIntroduce competency centers as a means of improving deliveryImplement an integrated applications management strategy Utilize program management as a means of controlling delivery
Agile delivery of integrated solutions within a predictable time frameUtilize proactive portfolio management to ensure effective implementation of investment decisions
Our
del
iver
ypl
atfo
rmIn
tern
al a
nd e
xter
nal
stak
ehol
der e
ngag
emen
tO
ur v
alue
-add
to A
nglo
Pla
tinum
- 13 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Agenda for discussionAgenda for discussion
1. Understanding the business objectives of an Industrial IT program
2. Key considerations across the EA stack influencing the design
3. The importance of an effective approach to architecture
4. The IIT applications and technology architecture at Anglo Platinum
5. Key functional MES requirements for the minerals processing industry
- 14 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
A sustainable approach to real time information-based decision making in the mineral processing industry requires a layered architectureA sustainable approach to real time information-based decision making in the mineral processing industry requires a layered architecture
Minerals processing
execution (MPX) functions
Minerals processing
execution (MPX) DB
Field devices
Control systems
Minerals processing execution systems
Information Management
systems
Supervisory systems
Programmable logic controller
(PLC)Objects DB
Robo labControl(RLC)
Weighbridge(WB)
Laboratory information
management system (LIMS)
Plant Historian 10 sec Analytical results
Enterprise applications
Operational performance management
(OPM)
Metal accounting (MA)
Enterprise resource planning(ERP)
Metal forecasting (MF)
Processing database
Enterprise data warehouse
Robotic instrument
(RI)
Controller Interface
node
(CIN)
Soft sensor
(SS)
Addressable field device
(AFD)
Weigh bridge
(WB)
Analytical instrument
(AI)
Master data flow
Functional integration
Trusted data
Application
Device
Sample prep(SP)
Addressable analytical instrument
(AAI)
Robotic instrument
(RI)
Robo labControl(RLC)
SCADA100ms
Advanced process control
(APC)1
sec
Process control
MetalAccounting
labProcess
control lab
- 15 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
The nature of the installed base often requires a combination of centralized and decentralized deployment of architectureThe nature of the installed base often requires a combination of centralized and decentralized deployment of architecture
Information Management
systems
Enterprise applications
PrDB
EDW
OPM MA ERPMF
MPXMPX DBRefineries: PMR
MPXMPX DBRefineries: BRPM
MPXMPX DBSmelters: Polokwane
MPXMPX DBSmelters: Waterval & Mortimer
MPXMPX DBConcentrators: PPL section
MPXMPX DBConcentrators: Lebowa section
MPXMPX DBConcentrators: Rustenburg section
MPXMPX DBConcentrators: BRPM section
MPXMPX DBConcentrators: Union section
Field devices
Control systems
Minerals processing execution systems
Supervisory systems
MPXMPX DB
PLC ObjectDB
RLC
WBLIMSPH Lab results
RICIN
SS
AFD WBAI
SP
AAI RI
RLC
SCADA APC
Concentrators: Amandelbult section
Reg
iona
l lev
el, d
eplo
yed
as c
lust
ers
Plan
t lev
elC
entr
aliz
ed
Its im
plem
enta
tion
of a
n “M
ES”
ofte
n fo
rms
the
mai
n th
rust
of a
n In
dust
rial I
T pr
ogra
m
Spec
ific
upgr
ades
to p
lant
hi
stor
ians
may
be
requ
ired
Func
tiona
lly
may
exi
st, b
ut
need
s da
ta to
be
sus
tain
able
- 16 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Agenda for discussionAgenda for discussion
1. Understanding the business objectives of an Industrial IT program
2. Key considerations across the EA stack influencing the design
3. The importance of an effective approach to architecture
4. The IIT applications and technology architecture at Anglo Platinum
5. Key MES requirements for the minerals processing industry
- 17 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
The Industrial IT architecture is driven by the main functions, input and output data flows in each layer of the architectureThe Industrial IT architecture is driven by the main functions, input and output data flows in each layer of the architecture
1. To execute control instructions received from the control system layerField devices
1. Controls unit processes, typically a selection of machine controllers and addressable field equipment.2. Collects and reports these values to a PLC supervisory layer (e.g. WINCC), or an APC (advanced process
control) system.
Control systems
1. Real time supervisory executable control logic to ensure reliable and optimal plant operation. 2. Continually calculates and provides set points for the control system layer. 3. Provides MES with granular detail on reasons for plant failure, based on root cause analysis.4. Deploy “soft sensors” where a physical measurements are either impossible or not yet deployed.5. Execute in accordance with recipe (either internally selected, or instructed by MES)6. Unit process level blending within the smelters, based on feed stock on hand and projected from MES level.
Supervisory systems
1. Provides a logical framework, based on linked objects, within which the execution of process steps within a plant are managed. Tracks the execution of these process steps.
2. Performs continuous metal balancing across key plant unit operations and the plant as a whole, as well as across the entire metallurgical complex.
3. Provides material tracking and genealogy functions, and assigns material properties to tractable batches(either physical or logical, e.g. time-based) at plant level.
4. Provides a maintenance management and execution function at plant level, based on detailed information about fault root cause analysis.
5. Accepts forecasts from metal forecasting as targets for a period and optimizes and controls plant performance to this target, considering local plant conditions.
6. Receives logistics scheduling instructions from a scheduling system and ensures its execution at plant level. Manage macro blending from concentrators to the smelters.
7. It provides operational reporting and analysis functions to plant personnel, to support in-the-moment decision making requiring access to detailed plant level performance information.
8. Support event-based integration to other systems (such as SAP, LIMS, WB, logistics scheduling)9. Enables Enterprise wide Energy Management
Manufacturing execution systems
Main functionsArchitecture layer
- 18 -Anglo Platinum • Proprietary and ConfidentialEnterprise Architecture considerations governing the implementation of an Industrial IT strategy at Anglo Platinum by J van Tonder June 2008
Field devices
Control systems
Minerals processing execution systems
Information Management
systems
Supervisory systems
Enterprise applications
Minerals processing
execution (MPX) functions
Minerals processing
execution (MPX) DB
Programmable logic controller
(PLC)Objects DB
Robo labControl(RLC)
Weighbridge(WB)
Laboratory information
management system (LIMS)
Plant Historian 10 sec Analytical results
Operational performance management
(OPM)
Metal accounting (MA)
Enterprise resource planning(ERP)
Metal forecasting (MF)
Processing database
Enterprise data warehouse
Robotic instrument
(RI)
Controller Interface
node
(CIN)
Soft sensor
(SS)
Addressable field device
(AFD)
Weigh bridge
(WB)
Analytical instrument
(AI)
Sample prep(SP)
Addressable analytical instrument
(AAI)
Robotic instrument
(RI)
Robo labControl(RLC)
SCADA100ms
Advanced process control
(APC)1
sec
Potential future:Group sample
and assay results management (GSARMS)
Integrated architectures requires different stakeholder groups with traditionally disparate agendas to work togetherIntegrated architectures requires different stakeholder groups with traditionally disparate agendas to work together
Process Control
Automation vendors
IT Mega vendors
CommercialIT
• Rational design is a prerequisite for success, but does not guarantee it
• Team dynamics and cultural design are vital
• Relationships need to be nurtured