From Paperwork to Productivity: How Automating Pre-Start Checks Transformed a Mine's Operations

Manual pre-start inspections in mines can be risky and time-consuming, leading to missed checks and potential equipment failures. A recent project to automate pre-start checks has not only streamlined these tasks but has also revolutionised a mine's operational efficiency. This case study explores how automating pre-start checks, along with integrating corrective actions and work order creation into JDE (JD Edwards EnterpriseOne), became a game changer for mine operations.

The Traditional Pre-Start Check Process

Before automation, pre-start checks involved operators manually inspecting heavy machinery - a process that took considerable time and included logging details on paper forms, then submitting these forms for review and data entry. This manual process was cumbersome and fraught with issues:

• Inconsistent Record-Keeping: Paper forms could be misplaced or damaged, leading to gaps in records.
• Delayed Action: Identified issues often took time to be communicated to maintenance teams, delaying corrective actions.
• Human Error: Manual inspections depended heavily on the vigilance and expertise of the operator, increasing the risk of oversight.

The Shift to Automation

Recognising the inefficiencies in the manual process, the mine decided to automate pre-start checks using advanced inspection software. This software enabled operators to conduct inspections using mobile devices, automatically recording data and identifying issues in real time.

Key Features of the Automation Project

1. Digital Checklists: Operators used tablets with predefined digital checklists, ensuring all necessary checks were completed uniformly.
2. Real-Time Data Entry: Inspection data was entered directly into the system, reducing the risk of lost or inaccurate records.
3. Automated Issue Flagging and Notification: Identified issues were instantly flagged, triggering notifications to the relevant maintenance teams.

Integration with JDE for Corrective Actions

The real game changer was the integration of the inspection software with the mine's existing JD Edwards EnterpriseOne (JDE) Enterprise Resource Planning (ERP) system. This integration facilitated several critical improvements:

1. Automated Corrective Actions: When an issue was identified during a pre-start check, the system automatically generated a corrective action. These actions were prioritised based on the severity of the issue and assigned to a technician for further investigation.
2. Technician Review: Using the mobile app, technicians assessed the issue reported by the operator and determined the next action - including indicating to the system to create a work order.
3. Seamless Follow-Up: The system tracked the progress of corrective actions, ensuring they were completed in a timely manner. Automated reminders and escalation protocols were in place to ensure follow-up.
4. Work Order Creation: For more significant issues requiring detailed attention, the system automatically created work orders in JDE. This integration streamlined the maintenance workflow, reducing downtime, eliminating double entry, and improving operational efficiency.

The integration between the inspection platform and JDE eliminated the manual handoff between inspection findings and maintenance action - transforming a multi-day process into an automated, near-instant workflow.

Benefits Realised

The automation of pre-start checks and the integration with JDE brought numerous measurable benefits to the mining operations:

• Enhanced Safety: With consistent and thorough inspections, the risk of operating faulty machinery was significantly reduced, enhancing overall safety across the site.
• Improved Efficiency: Automating data entry and issue reporting saved time, allowing operators to focus on their core tasks rather than paperwork.
• Reduced Downtime: Automated work order creation ensured that maintenance teams were promptly notified of issues, enabling quicker repairs and less operational downtime.
• Data-Driven Decisions: The system provided comprehensive data on equipment performance and maintenance needs, enabling more informed decision-making across operations and procurement.

Key Takeaways

• Automating manual processes like pre-start checks can significantly improve efficiency, accuracy, and data collection.
• Integrating with existing enterprise systems like JDE allows for seamless information flow and streamlines critical workflows like corrective actions and work order creation.
• The benefits extend beyond efficiency, leading to improved safety, reduced downtime, and data-driven decision making.

Looking Forward

The success of this project paves the way for further exploration of automation technologies in the mining sector. Future advancements in areas like real-time monitoring and predictive maintenance have the potential to further revolutionise mine operations and safety protocols.

Mining companies looking to improve efficiency and safety should consider exploring similar automation solutions to streamline their pre-start check processes and integrate them with their existing enterprise systems.