Controlling Costly Equipment Maintenance in the Mining Industry - Hardcat
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Controlling
Costly
Equipment
Maintenance
in the Mining
Industry
M i n i n g se c t o r
Hardcat empowers
the mining sector to
embrace technology,
unlock opportunity
and improve worker
safety
The mining and resources sector are by nature a
highly complex industry. Its processes and
operations are intensive, risk-prone, and subject to
uncontrollable weather conditions.
The mining industry poses another unique challenge. Its
01 workers operate large complex equipment, in some
climatically hostile and extreme environments. With this
mixture, mine maintenance is no easy venture.
The typical mine maintenance manager has to contend with
many issues including continuous machine repair, aging
equipment, reduced funds, and worker safety concerns.
Mining accidents are on the rise, with eight mining deaths
recorded in the last two years (QLD, Australia). Late last year
(2019) the state government vowed to get tough on mining
bosses who fail to protect their workers.
Under a bill to be considered by parliament this year, mining
operators could be jailed and hit with hefty fines for deaths
on their mine sites. The government announced plans to
create an industrial manslaughter offence for the resources
sector. The charge would carry a maximum 20-year sentence
for company heads and fines of up to $10 million for firms
found to have been negligent.
The mining union CFMEU’s Queensland president Stephen
Smyth said in a statement. "This is a terrible start to 2020.
The industry must redouble efforts to end the tragic loss of
life in our mines."
www.hardcat.com
M i n i n g se c t o r
BHP Billiton
Nickel West -
case study
The organisation
BHP Billiton Nickel West is a fully integrated, world-class
nickel producer with a commitment to Zero Harm and
sustainable development. BHP Billiton Nickel West is the
world’s third largest producer of nickel-in-concentrate.
With excellent infrastructure and a focused leadership
team, BHP Billiton Nickel West exports around 100,000
tonnes of nickel in metal each year, employs more than
3400 operational employees and contractors. BHP
provides significant benefits to the Western Australian
economy and to the communities in which it operates.
02
The issues
BHP Billiton Nickel West
identified a major WHS/
OH&S risk at the
Kalgoorlie Nickel Smelter
with the issuing, returns
and maintenance of
respirators for their
mining staff.
BHP Billiton Nickel West was also unable to identify the
actual cost of the maintenance on this equipment and
therefore unable to charge this back to the appropriate
cost centre.
No definitive record of who was issued which
respirator(s)
The possibility of incorrect or faulty respirator units
being issued to workers
Critical respirator maintenance being overlooked or
incorrectly completed
www.hardcat.com
M i n i n g se c t o r
"Hardcat has significantly
streamlined the issuing, returns BHP Billiton
and maintenance requirements
for respirators within a
Nickel West -
storeroom environment” Hardcat solution
"All this was achieved while at
the same time addressing the The standard configured Hardcat solution
addressed all of BHP Billiton Nickel West
initial WHS/OH&S concerns” WHS/OH&S issues, and provided
maximum speed and accuracy when
issuing, returning and maintaining these
respirators within a storeroom
environment.
Hardcat was configured to provide a
number of specific reports which
addressed BHP Billiton Nickel West’s
WHS/OH&S compliance requirements.
Following an extensive evaluation
process, Hardcat solutions were selected
as the preferred vendor
03
and implemented a solution
based upon:
• Asset Management module
• Stock module
• Maintenance module
• Barcoding
• HardcatWeb Interface modules
BHP Billiton Nickel
West's Hardcat solution
allows workers to
efficiently and effectively
manage the issue, return
and maintenance of
respirators for their
mining staff while
addressing the WHS/
OH&S issues.
www.hardcat.com
M i n i n g se c t o r
BHP Billiton
Nickel West -
Hardcat
implementation
The implementation of the Hardcat solution addressed the WHS/OH&S issues around the
management of respirators. Hardcat's continued use has promote greater efficiencies and
time-savings, enabling staff to dedicate more of their time to other aspects of their jobs.
One version - single source of truth
04
BHP Billiton Nickel West have the benefit of a comprehensive asset register which provides
clear accurate visibility of their assets and equipment while providing highly detailed
tracking of all maintenance work carried out on these assets.
Leverage equipment suppliers
BHP Billiton Nickel West now have a detailed database with accurate historic logs and up-
to-date information. This enables future leverage of supplier relationships and warranties.
Solution ease of use
The Hardcat solution at BHP is very popular with workers primarily because it is easy to use
and they can see the benefits it brings to their jobs and safety. As as a result, employees
have been quick to embrace its use.
1. One version - single source of truth
2. Better leverage equipment suppliers
3. Time efficiencies and solution ease of use
www.hardcat.com
M i n i n g se c t o r
ADNOC
(GASCO) -
Hardcat solution
The organisation
ADNOC Gas Processing (formerly GASCO), a
natural gas producing company of Abu
Dhabi. The company uses Hardcat solutions
to track the usage of over 6000 tool assets
in 319 categories by 287 staff in the
centralised tool room of its Habshan 5 Plan
in UAE. The tools range from small hand
tools to chain hoists and large scale
maintenance equipment.
The issues
• No formal asset register software
• No asset tags or markings
05
• No automated way of tracing which
employee ID is issued what item
• No product categorization
• No issue and return history against each
item
• No system for inventory or maintenance
audit
• No standard list for location and people
• No automated identification of employee
whom the asset is issued
• Spread sheet asset register has no
security
• No system transaction history available
- who did what?
Hardcat implementation
• Reduced time to perform workshop
audits by 80%
• Reduce time to perform issue and
returns by 90%
• Reduce time to produce tool usage
reporting by 80%
• Ability to reports on complete audit
trail of individual tools and equipment
• Monitor consumable stock and spare
parts, usage and store levels
www.hardcat.com
M i n i n g se c t o r
RFID – making
"Adopting RFID mining safe,
technology saves secure and more
organisations time efficient
and money while
also providing Many leading organisations are taking advantage
of RFID’s capability to deliver benefits such as
comprehensive real time asset tracking, instant bulk auditing and
comprehensive governance and compliance over
visibility on the full life-cycle of individual assets.
Adopting RFID technology saves organisations
equipment time and money while also providing
comprehensive visibility on asset utilisation.
utilisation.”
RFID and CCTV
RFID triggering CCTV images is an important
06
deterrent in areas without physical security. Fixed
RFID readers installed at prominent entry and exit
points (unmanned or manned locations) will
automatically detect assets and workers moving
in and out of these doorways and chock-points.
RFID worker audit
Worker audits ensure that personnel are kept safe and
accounted for. It can be as simple as allowing only
identified staff into certain locations.
RFID and fixed readers
Fixed readers for doorways and choke-points.
Hardcat’s Sentinel software allows for automatic
registering of both assets as well as workers.
www.hardcat.com
Hardcat specialises in asset and equipment management software and services. Utilizing
the very latest technology such as passive RFID, optional web front ends, wireless and
GPRS PDAs and apps for asset management in the field. While offering the certainty of
success that only comes with an established product.
Hardcat software has been sold to literally thousands of the world’s most prestigious
corporate and government entities in more than 120 countries worldwide, and there are
Hardcat representatives based in every corner of the globe.
Australia (HQ) South Africa UK USA
Hardcat House Country Club Estate Unit 4 Lansbury Estate 701 South Carson
253 Park Street South 21 Woodlands Drive 102 Lower Guildford Street Suite 200-3824
Melbourne Woodmead Road Knaphill Woking Carson City
VIC 3205 Johannesburg 2191 Surrey GU21 2EP NV 89701
p: +61 (0)3 9695 5400 p:+27(0)82785 2747 p:+44(0)7713 152499 p: 702-589-5839
sales@hardcat.com sales@hardcat.com sales@hardcat.com sales@hardcat.com
Mining sector clients
ADGAS Ok Tedi Mining Limited
Advantage Petroleum T/S Shell Direct Pilbara Iron Company
(NSW) Pilbara Iron Company (Services) Pty Ltd
BHP Billiton Iron Ore Pty Ltd Pilbara Manganese Pty Ltd
BHP Billiton Nickel West Qatar Petroleum
BHP Billiton NW - Kalgoorlie Nickel Queensland Mines Rescue Service Ltd
Smelter QMRS
BHP Billiton Uranium SA Rio Tinto Cape Lambert
CITIC Pacific Mining Management Pty Rio Tinto Marandoo
Ltd Rio Tinto Rail Network Maintenance
Derfell Pty Ltd T/A Shell Direct (Vic/Tas) RTIO Resource Development
Fuelink Pty Ltd T/A Shell Direct Santos (SAMPANG) PTY LTD
GASCO Shell Direct (Sungold)
GASCO Habshaan Shell Egypt N.V.
INPEX Browse Ltd Syria Shell Petroleum
Insert actual Company Name here Tullow Ghana Limited
Insert actual Company Name here VivoEnergy
INTECSEA Yem Technology
Laing O'Rourke Australia Zinifex Century Mine
Minara Resources
National Petroleum Investment
Management Services
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