Xstrata Alloys – LIMS Implementation - LabWarelabware.com/CustomerTestimonials/2012SA/08...

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Xstrata Alloys – LIMS ImplementationImplementation

Disclaimer

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Disclaimer

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registered and/or operate.

Agendag

Introduction – Cynthia PotgieterS L dSystem LandscapeImplementationProject Management MethodologyUser Support

Technical - Msimeki MsimekiUser Creation and MaintenanceIntegration

End User – Mercia ArnoldtUser experience

Introduction

Global OperationsG h D f CGeographic Diversification – 20 Countries

Confidential© Xstrata 2011 5

Chrome and PGM operations across Bushveld Igneous Complex - World’s most valuable geological intrusion

Alloys OperationsChrome and PGM operations across Bushveld Igneous Complex - World s most valuable geological intrusion

Ferrochrome- 5 mines – 5.3 million tonnes ROM capacity5 mines 5.3 million tonnes ROM capacity

chromite pa- 20 furnaces - 1.97 million tonnes installed

ferrochrome capacity paPGMs

16,000

employees

Lion Smelter

Lydenburg

Helena

Thorncliffe

MototoloHorizon

BoshoekRustenburg

Waterval

- Western Bushveld ComplexEland – 313,000 oz per annum platinum in concentrate (steady state 2016)

- Eastern Bushveld Complex

Chartech

RhovanKroondal

Wonderkop

ElandJohannesburg

NelspruitMototolo 130,000 oz per annum platinum (steady state)

Confidential© Xstrata 2011Capacities refer to nameplate capacity i.e. 100% level

Smelters within the PSV

•Rustenburg Plant

•430 000 tonne of Ferrochrome p.a.

•Boshoek Plant

•240 000 tonne of Ferrochrome p.a.430 000 tonne of Ferrochrome p.a.

•6 Semi closed Furnaces with Bagplants •Two Enclosed Furnaces

Confidential© Xstrata 2011

Wonderkop Plant

•553 000 tonne of Ferrochrome p.a.

•6 Semi Closed Furnaces with bagplants•6 Semi Closed Furnaces with bagplants

•Agglomeration Capacity 1 2 million •Agglomeration Capacity 1.2 million tonne p.a.

• Bokamoso Plant since July 2007

• Lydenburg

• 396 000 tonne of Ferrochrome p.a.

• Lion (Steelpoort)

•360 000 tonne of Ferrochrome p.a.p

• Four Furnaces

•Two Furnaces

Project

SAP/MES/LIMS System Integration

Systems, Applications, and Products in Data Processing

MM PP QM

SD TSW

Virtual Server

Inbound (23)

Outbound (13)

Web 2 HistoriaLaboratory Information

ODBC(42)

IP.21(44)

Manufacturing Execution System

Weighbridge

SQLWeb

S i /Web.21(9)

IP.21(8)

Historian

Management System

SQL(6)

Service/ODBC

OPC for CIMIOScale Heads

CIMIO (46)Scanners

USBBalanceRS-232

Lab EquipmentTCP/IP

Programmable Logic Controllers

Project Structure

Project ilula

MESStream

LIMSStream

InfrastructureStream

The MES stream will redesign the processes

The LIMS Stream will implement the new

The existing technical infrastructure will be

Description Description Description

within the existing Manufacturing Execution Systems for future growth and additional capabilities

Laboratory system that will increase the accuracy and efficiency of the laboratories

upgraded to support the new systems

•New server hardware•Upgrade to Windows 2008•Upgrade to 64-bit

Thermal Transfer Printers and barcode Scanners will be installed in the laboratories and weighbridge operations to ensure data integrity and improve processes. Manual capturing will be replaced by printed barcodes and quick scanning

Hardware

Change Management

p y p q g

Project Management Methodology

• Xstrata have adopted Prince2 Methodology and all projects are governed by a strict PMO process.p

• Key Positions key to the success of the implementation were :• Project Sponsor• Project Manager• Change Manager• Subject Matter Expert

User Support

• Xstrata have adopted ITIL (Information Technology Infrastructure Library) in all its processes., these processes are subjected to annual audits from our external audit p p jteam, and include ;

• Service Desk• Application Management• Incident Management• Problem Management• Change Management• Release Management

Technical

LDAPLDAP

What is LDAP

• LDAP (Lightweight Directory Access Protocol)

• It is an industry standard interface used to retrieve information from a network directory (i e Active Directory Novell Directory Services etc)network directory (i.e. Active Directory, Novell Directory Services, etc).

How does LDAP work

• LDAP Authentication: • LIMS verifies the user’s password against the password configured

within LDAP and not a password stored and maintained within the LIMS database.

• Auto Creation of Users: Th LDAP i t f b fi d t bl th ti f• The LDAP interface can be configured to enable the creation of user accounts based on the configuration of the user account on LDAP. This function supports single-point administration of user account and password informationpassword information.

How does LDAP work

• User Field Mapping• The LDAP interface copies LDAP information to the LIMS_USER table

for a user account whenever the user account authenticates against the LDAP server. LIMS provides a mechanism to map LDAP server fields with LIMS_USER fields.

• Role Authentication• Role Authentication• When authenticating a user account against the LDAP server, LIMS will

use the role information configured on the LDAP server during the login. If no role information has been configured on the LDAP server the LIMSIf no role information has been configured on the LDAP server, the LIMS login process will use the roles configured on the LIMS user account.

Challenges

• Little knowledge of the LDAP functionality and LDAP sll(s).

Benefits

• Auto creation of user account(s) in LIMS

• Easier user account(s) management

• Single-point administration of user account and password information in LDAP.

• Easier synchronization of user account information between the Active directory and LIMS.directory and LIMS.

• Strengthens security

MES–LIMS Interface

What is the MES-LIMS Interface

• It is a Web communication interface between LIMS and MES (Manufacturing Execution system).

How does MES-LIMS Interface work

• Plant samples are triggered from MES and automatically logged into LIMS.

• Sample information come from MES (i.e. Sample_Text_ID, Sample_type, sampling point, inspection type, vendor, etc)

• Plant samples are cancelled only from the MES system which cascades down to LIMS to keep the two systems in Sync.

Why did we choose the Web interface

• It was a solution of choice; because it's a modern technology and it is robust.

Challenges

• Little experience on Web Services.• Hard to understand the communication protocols that were used by the

different systems.• MES send sample info to be triggered into LIMS and LIMS return extraMES send sample info to be triggered into LIMS and LIMS return extra

size of data (including sample results).• For Web Services it can be an issue on busy network(s)-

• How are we addressing this :– Upgrade MES driver to 64-bitUpgrade MES driver to 64 bit– Create staging table to only read data

that has changed, since the last

table read

Benefits of MES-LIMS interface

• Samples are logged immediately in LIMS when triggered in MES.• Controlled Sample cancellation.• Only authorized (reviewed) samples are reported (one source of truth).

Accuracy of results reporting• Accuracy of results reporting.• Timeous reporting of results

Benefits of Web Services

• Interoperability• - runs outside private networks• -Developers choose their preferred programming language.

Web Services are platform independent• -Web Services are platform independent• -Solutions have a longer lifespan• Usabilityy• -Allows business logic of different system to be exposed over the

network• Freedom to choose your Web Service you need• -Freedom to choose your Web Service you need.• -No need to re-invent the wheel, you can develop the business logic on

the client side.

Benefits of Web Services

• Reusability• -Easy to re-use the Web Service, no coding is required to deploy a Web

Service

• Deployability• -Deployed using standard Internet Protocols• -Easy to deploy over firewalls

The end userThe end user tiperspective

What we had before

• Typographical errors, delay in reporting, no traceability of samples and results.

• Resistance from both users and Lab’s clients.

• Excel documents- SAP

• Instrument checks and quality forms

• Path to follow when reporting results – Moisture

All possible through:

• Dedicated teams

• Support – consistent, high level support from top management and BSS team.

• Users well trained by LIMS Administrator and core Labware team – excellent delivery,Users well trained by LIMS Administrator and core Labware team excellent delivery, clearly understood.

What have now…..

• We have just had our 1st anniversary of LIMS live!, one year after implementation –satisfactory to allsatisfactory to all.

• LIMS has become a very beneficial aspect of our lab operations (real time saving –especially during month end).

• Increased accuracy and efficiency faster results and streamlined workflowIncreased accuracy and efficiency, faster results and streamlined workflow.

• Paper use has become less and analytical costs reduced.

• Lab personnel pride themselves in this achievement

What we are looking forward to…..

• Standardization of methods across all Xstrata Alloys Laboratories.

• SANAS 17025 accreditation on LIMS system

Questions?

Xstrata Alloys – LIMS Implementation - LabWarelabware.com/CustomerTestimonials/2012SA/08...

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