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Client Quote
"We made use of profiles in On Key to ease the task of sorting our stock values per commodity, supplier, type, etc. By February 2009, our stock levels were only MR22.667 on one Plant (a reduction of MR15.561 or 40% over 3 months!)."
(Kobus van Eeden – Maintenance Planning Manager for Minopex group)

Pragma Products
Operations Africa
Marthinus Burger
Tel: +27 21 943 3900
Fax: +27 21 914 7337
Cell: +27 82 410 0673
marthinusb@pragmaproducts.com

Key challenges / Project background

Minopex is a well established mature client utilizing On Key to increase the performance of physical assets via optimization and continuous improvement projects. Since the initial implementation, Minopex extensively invested in training of key role-players over the years and now the system is fully driven internally and enjoys great committed and ownership from Minopex users. This commitment is further amplified by an excellent relationship between Minopex and Pragma which keeps the communication channel open. When support is needed Minopex makes use of the Pragma Helpdesk and is always up to date with the latest developments by sound attendance at the Pragma annual user’s conference as well as the Pragma annual asset management conference.

The PRAGMA intervention

During the initial implementation all the essential business processes, supportive roles and responsibilities and training requirements were identified to implement and sustain a viable asset management system. This enabled Minopex to roll out additional sites internally and to maintain the improvement process and projects at established sites. The following two case studies prove their success:

Elandsfontein: (2 years in operation)

"We identified a cost saving opportunity on our inventory. According to On Key our stock on-hand was MR38.228 in December 2008. Then we analyzed the information from On Key to highlight the most expensive items, identified stock with short lead times and negotiated better SLA’s with our suppliers. We made use of profiles in On Key to ease the task of sorting our stock values per commodity, supplier, type, etc. Minimum and maximum stock levels were reviewed. By February 2009, our stock levels were only MR22.667 (a reduction of MR15.561 or 40% over 3 months!). These values come directly from On Key stock warehouse items total cost. Today (10 March 2009) this value is MR24.427."

Marikana: (7 years in operation)

"Crushing is one of our most critical processes as the throughput directly influences the productivity of the mine as crushing is the start of the production process. We experienced an alarming number of downtime incidents on the Cone crusher and started to investigate. We printed all the history from our On Key reports. Then we checked that the actual job card hard copies from files were correctly captured and justify the reports. The info proved to be accurate. We analyzed the failure analysis report from On Key to determine if the problem is shift, or operator specific. It proved not to be, although the majority of downtime was at night. "Blockages" proved to be the main reason for failures. After analyzing the root cause of 'blockages', oversize of raw material supplied by the mining contractor during the night shifts proved to be the problem. We negotiated better SLA’s which resulted in a decrease from 66 hours downtime in November 2008 to an average of 12 hours in January and February 2009. This is a reduction of 82% downtime in 2 months!"

Tools & Technology

• ON KEY – PRAGMA’s enterprise asset management system
• Seamless interface with Financial System

Performance Improvement

Key benefits

• Control over AM info management
• Structured formal business processes
• KPI standardisation across all sites
  

The BOTTOM LINE

• Downtime reduction of 82% for crushing
• Inventory cost reduction of 40%