Schauenburg uses Data Analytics and Artificial Intelligence (AI) to process Big Data provided by a number of sensors attached to underground vehicles to give our customers a holistic overview of the complete mine process. This ensures that the highest levels of safety and productivity is met and monitored in real time.
An Introduction to SMPO
Let us start with an analogy. Before there were smartphones (Example iPhone), there were plain button operated mobile phones (Example Nokia 3310). For this “step up” in integrated technology a mind shift change was needed for both the developers and the consumers. For most of the population it would be unthinkable now to go back to button operated mobile phone.
Digitalisation is the integration of digital technologies into everyday life. Its purpose is value creation – using technology to generate new ways of thinking.
Smartphones are the result of digitalisation of mobile phones. It is the hardware integration of a mobile phone, a GPS, a camera, a touch screen interface, an internet modem, biometric interfaces etc. paired with software applications that allows for an extraordinary amount of functionality that most of us cannot live without.
We see SMPO as the best available tool for true digitalisation of underground coal mining.
SMPO is a fully functioning, commercially available fleet management productivity optimisation system that utilizes mobile machine monitoring and smart device communication, connected to powerful software in control rooms, on desktops and on smart phones that allows for short interval control of an underground coal production sections, as well as being an enabler for longer term strategic decision making.
The vision is continued integration until the entire mine is monitored and managed through a single point, but in a modular setup allowing modules to operate independently and as an integrated unit. We aim to remove uncertainty. We want to build a digital ecosystem and through the monitoring of specific data points we can realise usage-based maintenance of assets.
There are many variables affecting the ability of production sections to operate at optimal efficiency. Their eventual impact on the output may be hidden or unknown.
In terms of section efficiency – we want the most time available for production activities; for equipment to be available and functioning optimally and we want the process of load, haul and offload to be as efficient as possible. To get to this ideal state we want:
These are just some of the opportunity areas. The SMPO system can monitor and analyse information to the extent that the root causes of inefficiencies can be identified and corrected in the shortest amount of time.
As an example – Reducing the cycle time (CM load time, SC tram time, FB offload time) by 30 seconds can increase production output by 16%. Typical cycle times can range from 250 to 400 seconds based on setups. With SMPO the root causes of inefficiencies can be identified and corrected.
This section covers some unique selling points, as well as the advantages of each. These are advantages that Schauenburg has over competitors. Some competitors are OEM solutions, some do not rely on their own information and some do not have adequate expansion capability to truly digitalise mining.
As an example –
SMPO is a modular piece of the full digitalised mine.
To understand the full functionality and business case in subsequent sections, we must explain some key concepts
SMPO was developed by Schauenburg Systems utilising in house R&D engineering expertise & coal production & mobile machinery specialists, as well as utilizing a professional software developer (> 40 software development engineers) to develop fit for purpose modular software.
Schauenburg Systems is the South African OEM of the hardware, with vast experience in the Mining industry, has more than 600 employees and is a Level 4 B-BBEE contributor.
Schauenburg Systems strategically utilized industry expertise by partnering with TAU5 (Mining Digitalisation and Consulting) as experts of the coal underground environment. The subject matter expert from TAU5, Quintin Coetzee has been involved in productivity optimisation initiatives and introduction of technologies to mines over the past 10 years.
Mobile machines communicate with each other through intrinsically safe RF hardware installed on mobile machines (See figure below). The devices create different zones around the machines. The machines can transfer information and keep record of its own activities. It thus becomes possible to obtain accurate combined and single machine load time, tram time and offload time information as well as machinery utilization information in a very cost-effective manner.
The more data points are monitored the more key observations can be made. Accurate data with high availability is then communicated to a wireless communication module connected to the mine data network. Information is available within seconds on surface.
The data can now be analysed, and information presented in value adding formats. These include: The control room management system, real time performance monitoring screens, smartphone application and underground smart devices. Some examples are shown below.
The active use and appropriate timed correction of inefficiencies highlighted through the SMPO system will conservatively result in a 10% improvement in production output that can be managed sustainably.
For illustration purposes: If we take a mine with 5 sections conservatively producing export coal at 65,000 tons output per section per month and we improve and sustain production output by 10%, it will result in 390,000 additional output tons per annum.
If we assume a conservative sale price in Rand of R950/ton then the additional revenue is R370,5 Million. If we assume that only 40% of the extra income results in profit (base costs remaining unchanged) then the profit can be ~R148 Million.
The SMPO Annual Opex cost for this sample mine of approximately R7,9 Million only represents 2% of the additional revenue conservatively generated.
For this typical mine to recover the SMPO Opex cost, a production output increase of only 8,300 tons for the whole year across 5 sections is required. This represents 0,2% of original production output.
The expected payback period based on the conservative 10% improvement is within 1-2 months of full implementation.
Very important: Apart from the other digitalization advantages offered as a result of SMPO use, it is also very unlikely that more basic systems will yield the same output improvements. SMPO continuously re-invests into product improvements.
This means that even if SMPO only offers a 1% improvement over another system, the benefit is an additional R37 Million in revenue as a result of that advantage.
SMPO adds data points that has not been monitored before and analyses data to provide clear information in near real time views and on post shift reporting platforms. Inefficiencies can be addressed, and the result of work performed can be monitored for effectiveness of interventions.
SMPO performs the following functions. It is:
The SMPO system will assist your site to improve production output through identification of the inefficiencies that directly affect output. A very low production output increase of only 0,2% will fully fund the SMPO annual operational expenditure.
The conservative expected improvement in production is 10% on what you would have likely produced, given circumstances and conditions. Full adoption of this system is imperative to get the full value out of it.
SMPO is not comparable to more basic systems or OEM systems (see the advantages in Section 2).
We have conducted a successful POC and a successful live trial with the team at Greenside Colliery and have shown the monitoring system and software to be safe, stable and reliable.
SMPO is a proudly South African initiative that is designed, manufactured and supported locally. As a team we have invested capital and resources into the development of this system. Our vision is to provide solutions that will grow the production output of South African mines to grow the South African economy.
Our product has significant expansion capability, allowing us to provide integrated solutions for different areas in your business.
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