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solutions, these will continue to What will the future digital mine look like?
Core mining processes – automating physical
8
strategy and practices in order How can mining companies achieve true digital transformation?
A measured and agile approach
19
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to completely transform the way The time to act is now 22
2 3
The digital revolution | Introduction
Introduction
The disruption of business models through
the advancement of digital technology has
Building upon this innovation theme
to focus on digital, we explore:
Digital is now
been a reality for other industries for many • Why digital is now a reality for mining impacting the mining
years. Digital is now impacting the mining
industry. Technology has advanced such
• What the future might look like and
what is possible
industry. Technology
that the barriers of high cost of entry, and
a very physical value chain are no longer • How mining organisations can take has advanced such
protection against large scale disruption. steps to protect themselves from
disruption and falling behind the
that the barriers of
By bringing together our understanding industry or new entrants, while also high cost of entry,
protecting against poor investments
of shareholder value, mining operations,
technology and analytics, we have developed or failure, through: and a very physical
an approach to the “digital mine” which • Developing a digital strategy value chain are no
helps mining organisations make the most and proactively managing digital
of the digital opportunity and avoid the transformation longer protection
many potential pitfalls that come with the
adoption of new technologies.
• Automating operations and against large scale
digitising assets
• Building a “digital mine nerve disruption.
Our recent “Innovation in mining” studies
centre” for data-driven planning,
examined current perspectives on mining
control and decision-making
innovation around the world.1 Among the 31
mining companies involved in the Australian • Implementing supporting
study, most agreed that successfully platforms and enablers
navigating the industry’s mounting • Leading a diverse, distributed
challenges and ensuring the long-term and connected workforce.
sustainability of the sector requires moving
beyond the status quo – doing things
differently by embracing innovation.1
4 5
The digital revolution | Why should the mining sector pay attention?
6 7
The digital revolution | What will the future digital mine look like? The digital revolution | What will the future digital mine look like?
future digital
stock and safety monitoring remote operations
8 9
The digital revolution | What will the future digital mine look like? The digital revolution | What will the future digital mine look like?
Core mining processes – automating A connected network of low cost, highly Remote operations, combined with all of the
physical operations and digitising assets capable sensors using Internet of Things Digital in action above, will result in fewer people in hands-on Digital in action
The core operational processes in the (IoT) technology will capture data in real Rio Tinto’s Mine of the FutureTM operational roles, which will improve A Canadian synthetic oil producer’s existing solutions for management of asset
time, to enable integrated planning, program centres upon driving productivity, safety, and reduce overall cost.
future mining value chain will be highly information were not delivering value to the business. The data managed within
control and decision support. production while improving health,
automated, a wide range of digital capabilities the existing systems was often difficult to find, incomplete or viewed as
will be deployed.
A “digital twin” is a digital model of the
safety and environment performance
through greater automation. Rio Tinto
Globally, 69% of mining untrustworthy. Clean-up efforts were met with limited long-term success due
to lack of data integrity controls, validation and enforcement within the systems.
Autonomous vehicles will improve safety,
physical environment constructed using
geological, engineering and asset information
has the largest fleet of autonomous
trucks in the Pilbara, and is widely
companies are looking
To address these issues, the company developed asset and enterprise information
productivity, and reduce cost (through fuel
and maintenance savings). Drones will be
such as ore body models, engineering recognised as a leading innovator at remote operation and management strategies, and selected and implemented a new engineering
drawings, parts catalogues and service and as one of the lowest cost
used for data collection, inspection, stock manuals. Data from sensors and location- producers of iron ore in the world. monitoring centres, 29% information platform. The next-generation template solution for management
of asset information has been developed and proven at scale through pilot
control, condition and safety monitoring.
3D printing of critical spare parts will
aware mobile devices can then continuously
improve the ‘digital twin’, as an accurate Earlier this month, Rio’s driverless at robotics and 27% at implementation at a major facility, built on principles of supportability, maintainability
and minimal customisation.
reduce lead times and inventory holding
cost. Wearable technologies will be used
reflection of the physical environment.
This begins by implementing standardisation
train program made its first complete
journey without driver assistance, unmanned drones. 3
DISCOVER & ESTABLISH EXPLOIT RESOURCES BENEFICIATE ORE MOVE PRODUCT SHIP TO CUSTOMER
10 11
The digital revolution | What will the future digital mine look like? The digital revolution | What will the future digital mine look like?
The digital mine nerve centre – Real time data derived from processing Central to enabling this will be an integrated
data-driven planning, control, equipment and machinery sensors during and well governed data platform to support Digital in action
and decision making operation will enable short interval control analysis across all time horizons, and a A major global miner with multiple iron ore mines in one Australian region moved its short-term production, planning and control
The direct benefits of automation and to identify key drivers of process variability, centre of excellence in data management, activities from the mine sites to its new remote operations centre.
digitisation in execution will be significant, and drive rapid and focused operational reporting and analytics, which employs
improvements. specialist data scientists and analysts. The new operations centre included the implementation of a supply chain visualisation tool that represents an end-to-end (pit to
and even greater value realised when the Drones for inspection, Integrated
data is used to plan, optimise and integrate stock and safety monitoring remote operationsport) view of the iron ore supply chain, showing key operational metrics in near-real-time, permanently displayed on large screens,
the activity across the value chain. More timely data from across the value with data sourced from 16 disparate systems. This was the first time that the client was able to see its total supply chain in one place,
chain will also enable ore-body models, Digital in action assisting decision-making for the whole business.
To fully leverage the automation Autonomous
of core mine plans, and financial models
Wearables for field to be
maintenance
equipment
Dundee PreciousDiverse
Metalsmobile
- a Canadian-
and operator safety connected workforce Pit Hub Rail Port Harbour
Pit to Hub (monthly) 80% Hub to Rail (monthly) 80% Rail to Port (mobthly) 80% Port to Harbour (monthly) 80%
operations, companies will need to rethink updated more frequently, and shorten the based international mining company Pit to Hub (daily) 80% Hub for Rail (daily) 80% Rail to Port (daily) 80% Port to Harbour (daily) 51%
the way in which they generate and process planning cycles. has combined innovative thinking ‘Digital Twin’ – Shipping Yard 1
Digitised IoT sensors for real time U PvP
and Geological
U PvP U PvP U PvP
information, utilise data-driven analytics data capture and integrated technology in one of engineering and
Digitised
20% 40% 20% 40%
15% 24% 30% 26%
Mine A
Data Site 1
Reporting and analysis of historical data will Broken Stock 75% 38%
Truck Crusher Stockpile 75% 38% 18% 10%
15%
Stockpile
27% 28%
Vessel
systems all the way from pit to customer.
T X T X
X X
opportunities for improvement learned exhibited the way in which a myriad Shipping Yard 2
The information layer or “nerve centre” from experience. of communication and location
Site 2
Mine B
50% 50%
of a digital mine will bring together data technologies, as well as software Broken Stock Digger Truck Crusher Stockpile Train Loadouts
Junction1
Car Dumper Stockpile Ship Loader Vessel
across the mining value chain in multiple Future insight will be derived from systems, can combine to create an
time-horizons, to improve planning, control historical analysis to improve planning,
Shipping Yard 3
simulate the integrated supply chain, and including features such as real time
Mine C
50%
50%
DISCOVER & ESTABLISH EXPLOIT RESOURCES BENEFICIATE ORE MOVE PRODUCT SHIP TO CUSTOMER
12 13
Digitised Geological IoT sensors for real time ‘Digital Twin’ –
Data data capture Digitised engineering and
asset information
The digital revolution | What will the future digital mine look like? The digital revolution | What will the future digital mine look like?
Support processes – re-imagined A lean set of corporate processes will be Shared services centres and Centres
ERP and automated support processes assisted by robotic process automation of Expertise will employ a mix of on-shore, Digital in action Digital in action
Finally, the effects of digitisation will extend (RPA), which will automate repetitive human off-shore and robotic workforce, with Automation is transforming the labour market. A global mining and metals organisation has
beyond the core operations and the flow of activities to reduce costs and errors, and increased human-machine interaction
DISCOVER & ESTABLISH EXPLOIT RESOURCES Deloitte estimates ORE
BENEFICIATE that by 2035 approximately
MOVE PRODUCT SHIP
been a relatively early TO CUSTOMER
adopter of RPA within the
artificial intelligence (AI) which will closely and new and different skills.
information to the supporting processes 35% of current jobs in the UK will be automated.5
support knowledge workers. mining industry. After an initial proof of concept
and systems of functions such as supply, Similar trends are expected in Australia and focused on the invoicing process in its global
HR, and finance.
The convergence of information technology A diverse, distributed South
INTEGRATED OPERATIONAL Africa. Robotic
PLANNING, Process
CONTROL Automation
AND DECISION (RPA)
SUPPORT shared services centre, it is now applying
tools provide the ability to automate repetitive
Mining organisations are going to be
(IT) and operational technology (OT), and
the integrated management of these
and connected processes including data gathering and data entry
automation within its supply function.
challenged to completely re-think their The objective was to automate the manual work
corporate structures, as new entrants
historically separate domains, is an enabler
for automation and digitisation of both core
workforce will expect by ‘doing what the user would do’ via a software
robot which securely logs into applications and of the supply team in expediting the material
to the mining industry without existing
corporate infrastructure are able to
and support processes. an enhanced user REAL TIME
works with the visible user interface to enter orders and to seek to increase expediting coverage
DATA PLATFORMS
information, navigate through screens and extract to more than what is currently just the top 25
establish new and innovative models for Fully integrated communications networks, experience consistent
Real time sensor data to
drive short interval control in execution, and process the results. vendors
Integrated well governed
due to thesupport
data platforms manual all
time consuming process,
processes
delivering their non-mining requirements. leveraging the Long Term Evolution (LTE)
spectrum, will support the mobile workforce
with the homereduce variability, and shorten
planning cycles
In other industries such as financial services, where
high volume of work and frequency
and all time horizons of updates.
14 15
The digital revolution | What will the future digital mine look like?
Digital in action
The convergence of IT and OT has been an increasing conversation point within the mining industry in recent years, and we are now
seeing many of the large global miners evolving towards organisational alignment – to remove the historical separation between IT and OT
environments – in search of lower operating costs and more efficient teams. Effectively delivering IT/OT convergence is as much a people,
culture and change management challenge as it is a technology project.
OT Application
OT COMMON
OT OT
Technology
Environment
Database
Middleware Technology
Operating System
IT IT Hardware
COMMON
IT
IT Application
Digital in action
BHP launches online freight platform
to sink shipping costs
Reuters, 26 January 2017
16 17
The digital revolution | How can mining companies achieve true digital transformation?
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The digital revolution | How can mining companies achieve true digital transformation? The digital revolution | How can mining companies achieve true digital transformation?
#1 #2 #3 #4 #5
Developing a digital strategy Automating operations Delivering the digital mine Implementing supporting Leading a diverse, distributed
and managing digital transformation and digitising assets nerve centre platforms and enablers and connected workforce
Rather than spawning disconnected From our experience with major To deliver on the digital mine nerve centre, Today, many roads to digital transformation As the digital mine becomes a reality, our Executives serious about reaping
initiatives, digital strategy has to be mining organisations in programs such companies must establish a capability are blocked by core systems such as ERP, interpretation of what work is and how it the benefits of the digital future must
motivated from the enterprise level and as autonomous haulage and remote to use data to resolve a wide range of which are often expensive to run and gets done is constantly changing. The consequently ask some hard questions:
clearly define the value of digital initiatives operations, we understand the benefits business problems. In essence, intelligent maintain, and inflexible for future changes. future of work needs to consider the impact • Can current incumbents make
to the organisation as a whole. and key considerations for successful business decisions will ultimately hinge on Upgrading core systems to cloud-based of human machine interaction on future this transition?
implementation. In this context, access to timely and relevant information, applications and platforms can deliver work, workforce, and workplace. The future
Digital initiatives are often focused on • How can they train for new skills
collaboration is critical as companies in all time horizons. total cost of ownership (TCO) benefits workforce will demand and expect an
the technical solution and are not always and capabilities?
will need to operate in an ecosystem (typically in the range of 20-40%) and improved user experience, based on their
driven by a well-articulated vision and of providers and partners, and will also • How can they foster a supporting
Most organisations only use a fraction improved user experience, as the capability experience as consumers.
strategy, nor a direct link to business value. need strong program management and inclusive culture?
of the data they are already collecting, let of these solutions, and the associated “as
Digital transformation should begin with and integration capabilities. alone the potential real-time volume that a service” business models, have matured. 74% of global business executives surveyed
an understanding of the desired future
state, and the value to be created. A key question is how many mining
could be captured via IoT, and many are still by Forrester state that they have a digital 74% of global business
struggling with limited business intelligence Around the edges of core systems there strategy, but only 15% believe they have the
A key challenge in this new digital era is the
organisations have really delivered on the
promise of remote operations centres to
capability from historical ERP environments are typically many manual processes and necessary capabilities and skills to execute executives surveyed
ability to deliver change at the pace that challenge and change their operations,
and non-integrated operational systems. spreadsheets. Complementary to core
system changes, RPA can replace some
that strategy.6
by Forrester state that
achieves short-term results (within existing including taking advantage of a global
constraints) while maintaining flexibility to skillset (most operations centres are still
Skills and experience in data science tasks currently performed by humans, The digital mine is an organisation they have a digital
enable longer-term transformation. New and analytics are in demand and scarce. presenting an opportunity for cost transformation, it requires a new approach
approaches can be tested in a pilot or
single product/single country focused).
Establishing the capability for an insight- reduction in support processes and to leadership, a culture which embraces strategy, but only 15%
sandbox environment, rolled out in phases,
or easily shelved.
Most asset-intensive organisations
driven organisation requires developing
and embedding data science and analytic
shared services. Mining companies should
embark on proof of concept and pilot
data-led decision making and diversity,
a new way of operating and diverse and
believe they have the
face challenges with management of
engineering and asset information
skills across the organisation, as well implementations to test the potential different skills and capabilities. This is no necessary capabilities
Another key challenge is the large number as the foundational data platforms and benefits and gain experience in a rapidly easy task for mining companies, which will
of vendors offering products and platforms
throughout the asset lifecycle, including
data integrity issues and time wasted
analytic tools. growing domain. increasingly find themselves competing for and skills to execute
to provide solutions for many digital
opportunities, but no single vendor has a
looking for documents. An initial step
scarce digital talent. To succeed, companies
must bring in these new skills whilst also
that strategy. 6
Engagement
Intent and Scale Platforms
Strategic
Disruptors Operational
Perspective Evolution
Experience
Digital in action | Deloitte Enterprise Value Map for Mining Operational Eng.
Evolution Platforms
Business Value Strategic
Objectives Disruptors
Shareholder Value 5 Experience Experience
Operational
Evolution Strategic
Revenue Growth Operating Margin Asset Efficiency Sustainability Engagement
Platforms Disruptors
Selling, Property,
Production Plant & Receivables Company Business Safety & External
Reserves Volume Price General Income Tax Reserves & Inventory Funds
Cost Equipment & Payables Strengths Continuity Wellbeing Factors
& Admin Resources
INNOVATION STRATEGY AND BUSINESS DESIGN
20 21
Deloitte Digital Transformation Copyright © 2015 Deloitte Consulting LLC. All rights reserved.
The digital revolution | The time to act is now The digital revolution | Authors
References
Nicki Ivory Andrew Swart Julie Harrison
1. The Innovation in mining: Australia 2016 study, p 2, conducted by Deloitte in association with Diggers and Dealers Partner | National Mining Leader Partner | Global Mining Partner | Human Capital
and the Association of Mining and Exploration Companies (AMEC). Accessed at https://www2.deloitte.com/au/en/pages/ D: +61 8 9365 7132 Consulting Lead D: +61 8 9365 7061
energy-and-resources/articles/innovation-mining.html M: +61 422 024 597 D: +1 416 813 2335 M: +61 404 820 005
2. Rio chief spruiks value over volume, The Australian, 15 February, 2017. nivory@deloitte.com.au aswart@deloitte.ca juharrison@deloitte.com.au
3. IDC, September 1, 2015. “Robotics, Transparency, and Virtual Reality: The Critical Role of Digital Transformation in Mining.
Accessed at http://www.idc.com/getdoc.jsp?containerId=prAE25879615 on October 25, 2016
4. International Mining, November 9, 2016, “Rick Howes’ ‘Taking the lid off’ makes an Outstanding Innovator.”
Accessed at http://im-mining.com/2016/11/09/rick-howes-taking-the-lid-off-is-an-outstanding-innovator/
5. Agiletown: the relentless march of technology and London’s response, p 5, Accessed at https://www2.deloitte.com/uk/en/
pages/growth/articles/agiletown-the-relentless-march-of-technology-and-londons-response.html
6. Forrester, 2014. Referenced in Decoding Digital Leadership, Deloitte 2016. Accessed at https://www2.deloitte.com/uk/en/
pages/public-sector/articles/decoding-digital-leadership.html
7. Talent for survival, Essential skills for humans working in the machine age, 2016. Accessed at: https://www2.deloitte.com/
uk/en/pages/growth/articles/essential-skills-for-working-in-machine-age.html
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