Australia’s Largest Coal Producer Improves Production Efficiency with Eka’s Plan Performance App
Coal mining companies provide the fuel necessary to drive the economy, but collecting and distributing natural resources can be challenging. It is important to optimize production, but understanding the root causes of plan deviations is difficult. It is impossible to optimize performance without first understanding the root cause of plan deviations. Creating one, accurate view of events is challenging since performance is tracked in different systems, including information captured from IoT sensors.
A large coal producer based in Australia did not have a system to effectively analyze control system data from equipment and provide key metrics on plan performance. As a result, it could not easily track the effectiveness of its operations plan or investigate the root cause of delays or reduced throughput.
Process inefficiencies increased production costs. The company was unable to create effective process improvements because there was little understanding and visibility into the root cause of plan failures. It used a manual system to pull data from existing systems and analyze it to evaluate separate causes of plan misses. This process was inefficient and inaccurate.
The company implemented Eka’s Plan Performance app to track all its activities, resources, and equipment performance in near real time. The solution analyzes daily throughput and compares planned vs. unplanned tonnages and in-sequence vs out-of-sequence events. It monitors for unexpected activities as well as on-time, late, and early events. In addition, it consolidates internal and external data to provide a complete picture of disruptions to the production team.
Eka’s Plan Performance app helped the business identify bottlenecks in operations and evaluate equipment performance, providing better visibility into plan execution.
The solution also helped in evaluating performance by providing a complete understanding of root causes for production delays by tracking data from internal and external data sources. This essentially included data from existing trading systems, weather data, and IoT sensor inputs. The company also increased its productivity with continual improvement programs by evaluating approaches that produced the best results.
Today, the coal company tracks events faster, benefits from improved efficiency, generates reports faster, and from enhanced risk mitigation measures.