Close

Expanding Our Digital Footprint

DRISHTI

Our Drishti programme is running successfully and provides targeted benefits. This year, we have added many modules into this programme, including integration of different systems, advanced process controls, AI/ML based data analytics, use of IoT technologies, and remote monitoring and control.

  • Key Actions Taken
  • Benefits

Use of AI/ML based analytical modules

Use of image processing technologies enabled us to identify any unsafe act or conditions on the shop floor Developed this model to check the physical quality of FG, and detect defects to take timely corrective action

Integration of shaft system with integrated data platform

Real-time visibility of operations, cycle time analysis, fill factor monitoring, and improvement

Use of IoT technologies to deploy smart sensors on remote equipment

Real-time monitoring and control of remote assets, like steam trap health, vibration of critical drives, water ponds level and UG fleet utilisation etc.

Condition-based monitoring and Real-time Reliability Health Index (RHI) of critical assets

Using real-time data of critical assets, we have developed CBM and RHI which have helped in improvement of availability, reliability, and efficiency of equipment

Integration of ventilation fans and sub-stations in UG mines

Real-time assets health and performance monitoring, faster troubleshooting, and increased UG fleet utilisation

Deployment of advanced process control at mills

1% increase in metal recovery and optimised concentrate grade control with the help of APC. Tighter process control with reduced standard deviation

Smoke hours drilling using automation features

~ 10% additional production drilling by utilising automation features and tele-remote operations of drills during shift change over

Integration of laboratories with integrated data platform

Real-time visibility of analytical data to operational team to enable timely action. Lab data is integrated with DCS to improve operational efficiency and product quality

Utilisation of 3-D mine visualisation for assets tracking

Real-time visibility of underground fleet has helped us to reduce the ramp jam incidents and duration and improve asset utilisation

Automated process data analysis: Real-time process score card, CpK analysis and SPC charts, automated process deviation alert, and SAP notification

Real-time access of process analytics enabling process optimisation by quick response

CASE STUDY

Improving Recovery through APC
MAXIMISING THROUGHPUT AND OPTIMISING ENERGY CONSUMPTION

The Advanced Process Controller (APC) is used at Hindustan Zinc in the grinding and flotation processes. It is meant to improve recovery of metals and optimise energy consumption in the beneficiation process. APC is a control system that operates on the principle of ‘Stabilise & Optimise’ that helps to attain optimal throughput and optimise metal recovery balancing. It also helps to keep the concentrate grade within acceptable limits.

As part of the Initiative

  • APCs were implemented for grinding & flotation operations (lead and zinc) in RA and SK mills
  • APC was used to maximise the throughput and improve recovery of metal
  • It was also concurrently used to maintain optimum levels of concentrate grade

Benefits

  • Stabilisation of process parameters across milling plants
  • Significant reduction in standard deviation of key process parameters
  • >1% improvement in Zn & Pb recovery, resulting in additional volume
  • Significant improvement in grade control of the concentrate and reduction in its variability

NORTHSTAR

NorthStar/Hexa is our in-house reporting, visualisation and data analytics tool assisting teams across departments. It provides us with real-time data to enable sophisticated data-driven decision-making. NorthStar/Hexa has empowered both business functions and on-site teams to effectively leverage data to streamline operations. It has facilitated stakeholders in taking important business decisions independently through process automation across locations.

NorthStar was conceptualised and implemented to build a single source of truth to enhance data governance, visualisation, and reporting. It was envisioned to engage with different departments/functions by analysing their working and implementing digital transformation to derive maximum business value. In our efforts to digitally transform the organisation through an end-to-end trusted data governance tool, insights from NorthStar have helped streamline processes and reporting in several departments, including Operations, Commercial, Finance, and HR. These insights have led to improvement in efficiency and enhanced performance.

Since its inception in 2020, NorthStar has assisted more than 500 employees across multiple locations. It supports employees with more than 30 live dashboards and over 100 live reports with varied frequency of circulation ranging, from twice a day to once a month. It has, over the past two years, evolved into a single repository of data, originating from more than six data sources. Business stakeholders at all levels, including top management, have reposed their faith in the dashboards and reports, which have facilitated the accomplishment of crucial business goals, and has helped us achieve one milestone after another.

The journey of NorthStar’s evolution has not been easy. In the early days of implementation, it was an onerous task to enable departments to realise the business value of automated reports and dynamic dashboards. Creating awareness among functions, by targeting low hanging fruits to highlight output and further scope, was the most important step for the implementation of this system. Further, integration of various data sources onto a single platform needed co-ordination and co- operation among different functions. Building a bridge of trust between the owners and users of the dashboards and reports, to create a trustworthy and engaging ecosystem to derive maximum business value, was indeed a challenge. Creating a framework to evaluate user requirements, feasibility parameters, and business impact was a crucial step on this journey to ensure the success of this project.