Engineering & Mining Journal

JUN 2016

Engineering and Mining Journal - Whether the market is copper, gold, nickel, iron ore, lead/zinc, PGM, diamonds or other commodities, E&MJ takes the lead in projecting trends, following development and reporting on the most efficient operating pr

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58 E&MJ; • JUNE 2016 www.e-mj.com COMPANY PROFILE-PAID ADVERTISEMENT Today's mining market is a challenge, but Joy Global has the solutions to help mining oper- ations reduce costs and increase productivity, while achieving or exceeding operating and financial goals. The company's JoySmart Solutions are integrated offerings of its smart connected products and systems, advanced analytics and direct services, customized to solve the tough- est mining challenges. Smart, connected products deliver data to JoySmart experts, who partner with custom- ers through the company's worldwide direct service network. The analytics produced allow the JoySmart teams to provide direction, antic- ipating service needs and optimizing machine productivity to drive results and move the needle in mine performance. What does a JoySmart Solution look like? In Australia, JoySmart experts helped a coal mining operation improve availability for its 4100XPC DC and 4100XPC AC P&H; shov- els by providing better visibility on potential upcoming causes of downtime. Major component failure events needed to be controlled to minimize impact against bud- get, and an enhanced solution was required to improve margins and maximize shovel operation for the mine. The JoySmart team proposed implementation of a newly-devel- oped automated monitoring system that trawls through machine data with the ability to detect any changes in component behavior to predict an onset of failure. "The key for us was to create an algorithm that was sensitive enough to pick up small changes in component indicators while not creating unnecessary alarms," said Trevor Griffiths, product performance manager with Joy Global. The strategy was to build on the existing partnership by employing new technologies and concepts to reach the next level of per- formance needed in today's mining indus- try. Implementation needed to be quick and effective, with a six month "proof of concept" plan to determine whether the new approach would continue JoySmart product specialists quickly iden- tified areas of focus that would be priori- tized to achieve improved reliability: major equipment (motors, transmissions, gearing, bearings); lubrication; and air supply. Major equipment monitoring provided the necessary risk management element, whilst air supply and lubrication were identified as systems that had the most impact on shovel reliability. An engagement strategy was discussed and implemented that had clear lines of commu- nication and accountability. Both companies understood that this needed to be a partnership with common goals and a unified approach. Using collected sensor data, JoySmart Solutions experts deployed predictive models that could analyze real time sensor data to determine if any of the identified major equip- ment or systems was starting to drift from "normal" operation. On a daily basis, JoySmart product specialists would intercept any model detections and then report out with a recom- mended course of action, giving it a priority rating depending on the component type and severity of the detection. Toward the end of the six-month trial peri- od, the combined shovel availabilities hit the target of 92 percent eight weeks in a row. One of the main drivers of change, the need for consistency in machine availability, was now being achieved. No major equipment failed during the six-month period. The benefits of the part- nership were so clear that a planned review of the trial period was deemed unnecessary, and the customer decided to proceed with a long-term partnership. Working together with the JoySmart Solutions team, the customer continues to improve performance every week through new ideas and strategies developed. JoySmart Solutions have been used to increase productivity, optimize performance, extend equipment life and more in applica- tions worldwide, including surface and under- ground coal mines, rock salt and copper. To find out more, and read the lat- est case studies, visit www.joyglobal.com/ services/joysmart-solutions. Case Study: Mining Operations Work Smarter With JoySmart

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