80% of operational cost in mining operations comes from its logistics. The Mining industry continually searches for ways to streamline costs and increase the efficiency of its logistics. With an increased demand for more transparency, it is now more important than ever that a clear line of sight is available for tracking fleets and assets used for mining and transportation of the ores.
Efficient fleet management leads to reduced operating costs, minimum losses, increased utilization, effective management of human resources and clear bookkeeping. OTS has been deployed in mines across India for a decade. It is reliable enough to operate smoothly in the harshest of environments and over the most difficult terrain across any type of mining operations.
OTS is a proven track and trace solution for Mining.
OTS is used for fleet management & asset tracking in mining operations. Thousands of workers work in potentially dangerous working conditions & stakeholders have many valuable assets on these sites which are difficult to monitor. Using OTS, stakeholders can now maximize operational efficiency without compromising on workers safety. They can also have accurate transport analytics with timely and authentic data generated by OTS.
Challenges in MINING
- Optimising productivity at the lowest possible cost
- Improving miners safety during mining
- Minimising human errors that lead to improper accounting
- Capturing accurate & real-time information regarding production and transport
OTS Includes:
- INTEGRATED TRAFFIC MANAGEMENT SYSTEM
- UNMANNED WEIGHBRIDGE AUTOMATION
- ASSET TRACKING
- INTERNAL TRACKING (SHORT-HAUL) WHEEL LEADERS, EXCAVATORS, DUMPERS
- OUTBOUND (LONG HAUL)
- PERSONNEL TRACKING
1. Pit Tracking
Trucks, wheel loaders/ Excavators are fitted with zigbee devices. The supervisor will use a zigbee based configurator device to assign details related to the pit in the wheel loader device from a distance of 10 to 20 mts away. The wheel loader device creates a geofence around it, any truck entering this geofence and waits for the configured amount of time. The data from the wheel loader device gets written into the truck zigbee device along with the GPS coordinates. Once on the weighbridge, the details of the pit which the truck is carrying are saved against its weight.
Machine efficiency is calculated for wheel loader based on the number of trucks filled by wheel loaders within a given period of time.
2. ROM
Hopper IN Point78OL
Trucks coming from the pit get weighed at the weighbridge which gives us the details of Pit and the weight carried by the truck. This material is dumped into the number of input hopper which has a fixed RF station. Once at the the hopper input, the trucks get read at these points by the hoppers. We can calculate the total weight of the material extracted from the pit and the unloaded material into the hopper input for ore refining. Hopper Out PointAfter refining the ore needs to be weighed and stacked. The output hoppers are fitted with fixed RF touch points where the trucks will be loaded. The trucks once underneath the hopper gets scanned by the fixed RF station. Once on the weighbridge the RF touchpoint at the weighbridge will scan the truck and weight will be saved against the output hopper details.
We can get the total weight of the refined iron ore, the total waste after refinement against the total quantity of raw material unloaded into the input hopper.3. Water Tanker
Water tankers used for spraying water within the plant need to be weighed after the tanker is filled and after the tankers have unloaded the water. Fixed RF station at the weighbridge will scan the tag and capture the weight i.e Gross and Tare. Based on the data captured the total quantity/ weight of water sprayed or unloaded will be calculated.
4. Scrap weighment
Scrap material generated within the plant needs to be weighed and to be stacked for sale. The truck gets loaded with the scrap material and is moved on to the weighbridge for weighment. Fixed RF station at the weighbridge will scan the tag and capture the weight, based on the data captured the total Net quantity of scrap will be calculated.
5. Equipment Efficiency
Its is a GPS based system used to track and calculate efficiency of the vehicles within the plant premises. All vehicles with in the plant are fitted with GPS devices. Geo-fences are created at strategic locations within the plant.Efficiency calculation is done based on the time spent by the Vehicle within a certain Geo fence.
1. Source/ Destination
Weight of the truck loaded with ore for transportation needs to be weighed at source and at destination to ensure safe transport of material with out and pilferage. The trucks after loading get scanned at the Fixed RF station at the weighbridge. Based on the data captured the net quantity of ore will be calculated at source against a particular STO(stock transfer order). At the destination the same process of weighment is repeated, the net weight at source is matched with the net weight received at destination.Only the weight which falls within the permissible limit/ tolerance limit is allowed to be saved. This ore is stacked at the respective stacks. This process works in offline mode.
2. Jetty/ Barge
Ore after reaching the destination needs to be exported. The truck is loaded with the ore and moves on to the jetty weighbridge fixed with RF touch point. When the trucks are scanned first, the gross weight is saved. While unloading the tag of the trucks goes out of scope, when the truck tag come back in scope the tare weight of the truck is saved. Based on this we can calculate the net quantity unloaded into the barge.
3.Scrap
External scrap movement has 2 processes Inbound and outbound. In Inbound scrap movement the trucks from other plants are brought to one single location where the scrap is weighed and stacked. The truck details along with material description and weight gets saved through the RF touch point installed at the weighbridge. The same process is followed for Outbound process where the trucks gets weighed for export of scrap.
4. Yard management system
Yard management helps in efficiently allowing transporters to allocate vehicles for transportation and vendors to issue contracts for transportation of materials. A web or an Android application will give flexibility to the vendors where they can allocate or issue contracts for transportation to all the transporters. The transporters will be able to bid for the contracts and also assign trucks for hauling or transportation of materials before they reach the plant premises.
Integration
- SAP/ERP
- DMG
- EWB (E-Way Bill)
The result is OTS, a high performance tracking solution that combines both Asset tracking & fleet management with consignment tracking functionalities for further tracing of the delivered cargo and asset tracking to any scale, globally. A complete end to end traceability solution by Perceptron software labs.
