Coal Mining SAP Best Practices
Purpose, Benefits • Purpose • This scenario describes the complete process from mine to stockpile as an example. It could be also used to describe the process from a quarry to stockpile in the building material industries. The scenario includes crushing of the rock and moving to a stockpile. • Benefits • PI (Process Instruction) sheets are used to manually record production achievement. The PI sheet provides a user friendly interface that allows production operators to enter data in a customized manner. • A production batch is created for the process order, which allows quality characteristics (assays) to be recorded in the system. This batch represents the quantity and quality of the crushed coal produced for the time period specified by the process order. The batch characteristics for the stockpile batch are then adjusted based on a weighted average calculation of contributing batches of coal. • PM measurement point is integrated, truck related KPI is stored in the created measurement documents.
Required SAP Applications and Company Roles • Required SAP Applications • SAP enhancement package 6 for SAP ERP 6.0 • Company Roles • Production Planner • Shop Floor Specialist • Equipment Operation Manager • Warehouse Manager • Key Process Steps • Create a Process Order for Hauling (crushing) Coal • Control Recipe Monitor • Maintain Production Data Using PI Sheet • Process the Entered Production Data
Detailed Process Description • Loading and Hauling in the Mine • In the first step of this scenario coal is extracted and hauled to the crusher. Actual operating details (hours, tonnes, fuel used) for each haul truck are entered into the PI sheet. These are then posted in background to update the logistics, financial, and plant maintenance information in SAP ERP. ROM Coal produced will be used as feed-stock for the crushing process. Truck details are passed to Plant Maintenance and can be used to schedule and manage future maintenance activities.
Detailed Process Description • Crushing Coal • A second process order represents the crushing process. ROM coal feed-stock is passed through a crusher to create crushed coal. Again a PI sheet is used to record the production data. For the crushing operation a production batch is created for the process order. This allows quality characteristics (assays) to be recorded in the system. This batch represents the quantity and quality of the crushed coal produced for the time period specified by the process order. • In the PI sheet for crushing the operator selects the stockpile (or stockpiles) onto which that day’s production is transferred. A batch to batch movement is carried out to move the production batch quantity from the process order onto the stockpile batch. The batch characteristics for the stockpile batch are then adjusted based on a weighted average calculation of contributing batches of coal.
Contd. To Page 2 Process Flow Diagram Coal Mining (Mining Operations) Event Loading and Hauling in the Mine Production Planner 4.1.1 Create Process Order for Hauling Coal 4.1.6 Displaying the Process Order for Hauling Coal Production Worker 4.1.2 Create Production Data Entry Sheet 4.1.4 Entering Production Data using PI Sheet 4.1.5 Processing Entered Production Data 4.1.7 Displaying Process Order Confirmation (Optional) Generic EAM Functions 4.1.3 Display Measurement Document 4.1.8 Displaying Measurement Document Quality Manager 4.1.9 Changing Batch (Optional)
Contd. From Page 1 Process Flow Diagram Coal Mining (Crushing Operations) Event Crushing Coal Production Planner 4.2.1 Create Process Order for Crushing Coal 4.2.5 Displaying Process Order for Crushing Coal Production Worker 4.2.2 Creating Production Data Entry Sheet 4.2.3 Entering Production Data for Crushing Coal 4.2.4 Processing Entered Production Data 4.2.6 Displaying Process Order Confirmation (Optional) 4.2.7 Displaying Material Document for Material Quality Manager 4.2.8 Changing Batch (Optional)
Diagram Connection Legend <Function> Hardcopy / Document External to SAP Financial Actuals Business Activity / Event Budget Planning Unit Process Manual Process Process Reference Existing Version / Data Sub-Process Reference Process Decision System Pass/Fail Decision