Implats revamps maintenance system

When EDS and Mincom helped Implats Refineries convert to a new computerised maintenance system, the benefits were dramatic and immediate.

Impala Platinum Refineries, in Springs, is a huge facility that processes all of Implats` precious and base metals, as well as those of several other independent mines. With an annual output of more than a million ounces of platinum alone, it is the second largest plant of its kind in the world.

Maintenance, at this continuous-process facility, is both a critical function and a major contributor to operating costs. Apart from the vast infrastructure of fixed equipment, the plant has large numbers of rotatable units - for example, some 1 800 motors alone. For optimum efficiency, each component must be tracked, inspected and serviced at optimum intervals, and the working cost of the unit monitored.

With its old system, this was difficult if not impossible. According to Gary Stewart, senior planned maintenance officer at Implats Refineries, tracing movable equipment was a headache, and keeping track of equipment costs a nightmare.

"We realised the solution was to have a planned maintenance system, integrated to all of our other systems such as inventory, finance, HR and so on," he says. "We knew it would be difficult to implement, but on paper it seemed the benefits would ensure a good return on investment."

Implats outsourced its information technology to EDS in 1995. Since then the global information services company has upgraded and managed the mining group`s IT infrastructure and - its most far-reaching project - implemented the enterprise resource planning system MIMS.

"Together with EDS we explored our options, and came to the conclusion that the MIMS planned maintenance system - with some customisation - would best suit our needs. I`m happy to say we were right."

Stewart says the implementation was "a total success".

"It took only four months to get the system up and running in line with our requirements. EDS provided excellent expertise that helped us take the project from design through to implementation, on schedule and within budget. Setting the new system up was quite a challenge; using it now is quite easy."

And the benefits of system quickly became apparent. Among the most important are:

• The location, status and maintenance cost of all equipment can now be precisely monitored. As a result equipment is more efficiently utilised, servicing is scheduled at optimum intervals (and in line with the requirements of health and safety legislation), and the incidence of breakdowns is reduced.

• Through better planning, maintenance personnel can now be assigned more efficiently; the availability of supplies can be assured while keeping inventory levels down; and all sections can be given ample notice of major maintenance work.

• The working costs of equipment can be tracked with more ease and certainty than ever before. Information is available immediately, on line and in a wide variety of formats.

The new planned maintenance module is a complex system that has necessitated some big changes in the way people work.

"We knew it wouldn`t be easy getting the system to do what we wanted, and then getting people to use it effectively. But as soon as it was up and running the benefits quickly became apparent - not only for the company, but for the users too.

"I believe the savings for Refineries have been considerable. It`s hard to quantify - before putting in the system there was a lot we weren`t able to measure. But in terms of saved man hours, better utilisation of equipment, better inventory and financial management ... there`s definitely been an enormous benefit."