Optimizing asset performance is a strategic priority in the mining and metals industry (Part 2)

Do you want to learn more about data governance for performance indicators (KPIs)? Check out our latest blog article on this topic.

Downtime, whether planned or unplanned, is one of the main factors affecting asset availability, directly impacting the company's overall equipment effectiveness (OEE). Reducing downtime is essential for operational profitability.

Key strategies for effective downtime management:

• Root cause analysis of downtime helps better understand recurring downtimes and identify equipment failure points. This approach helps develop sustainable strategies to reduce and eliminate these incidents in the future. Proactively addressing current issues not only resolves current problems, but also enhances equipment reliability in the long run. Using Pareto charts to identify the main causes responsible for most of the downtime helps target significant causes.

• Adopting preventive and predictive maintenance strategies, by using analytical tools to detect anomalies before they become critical, can help reduce unexpected downtimes by anticipating potential failures. Data-driven maintenance based on historical trends helps optimize costs (through better work coordination and planning) while extending equipment life.

• Implementing exchange interfaces enables automatic retrieval of equipment status directly from PLCs, production tracking systems (MES) and other expert systems. This allows for real-time anomaly detection while automating the initiation of maintenance processes. As a result, it improves asset intervention planning, thereby reducing the risk of unexpected downtime.

• Training teams for quick and effective emergency response is crucial for minimizing interruptions and ensuring a fast return of assets to production. Clear protocols and well-prepared teams help reduce the impact of breakdowns while minimizing risks to operator safety and product quality.

In operating systems, it’s best to create links to standard operating procedures (SOPs) to guide support teams to the necessary documentation. This provides easy access to troubleshooting guides from past incidents, saving time and creating a knowledge base for new operators. Additionally, integrating intelligent alarm management enables fast and accurate anomaly diagnosis while prioritizing critical issues, directing support teams to the most relevant actions to take.

To learn more about how important alarm management is, read the following BBA blog article: Good alarm management pays off! 

However, poor downtime management can lead to significant health and safety risks and environmental impacts. For example, a poor time-loss analysis that suggests applying an inappropriate fix to an asset can create dangerous conditions, such as keeping faulty equipment operating, thus increasing the risk of accidents or failures. These situations can also lead to pollutant emission leaks, harming the environment and compromising team safety.

Would you like to dive deeper into these topics with other industry leaders in mining and metallurgy? Attend our next virtual round table to exchange best practices, share experiences and discuss pitfalls to avoid. This is an excellent opportunity to explore actionable solutions together to improve asset performance.

Sign up now for our waiting list by emailing MES@bba.ca. You’ll receive updates on event dates and an exclusive invitation to this collaborative event. Don't miss this unique networking and learning opportunity!