OneSteel Whyalla MES
The Client
OneSteel Limited is a vertically integrated steel producer and iron ore exporter. Recently, OneSteel has been engaging in a major capital works project to upgrade its infrastructure to support a substantial increase in iron ore exports at its Whyalla operations.
The Problem
To support operations of the new infrastructure, OneSteel required a system that could scale with the increase in tonnes and maximise the opportunity to export hematite, minimise waste, reduce costs, whilst maintaining quality and blend specifications.
The systems supporting the existing operations were based largely around disparate spreadsheets, spread between OneSteel and its four contractors. This presented problems with the visibility, reliability and timeliness of information available to decision makers. The volume of spreadsheets in use was unwieldy and was not suitable to scale.
These people centric processes, combined with insufficient documentation, were not suitable for a major strategy.
The Solution
OneSteel engaged Optika Solutions Pty Ltd to provide strategic systems advice as well as project management and integration services for the implementation of a Manufacturing Execution System (MES).
MES are a family of systems that provide real time information and insight into operations, and form the bridge between the boardroom and the plant floor. MES provides a single source of the truth and presents the right information, to the right person, at the right time, to facilitate the right decision.
The solution included systems such as:
· Material tracking
· Stockpile management
· Overall Equipment Effectiveness (OEE) reporting
Optika consultants worked collaboratively with software vendors to implement a “best of breed” solution, utilising two “off the shelf” software products.
Results
The implementation of the MES was successful, providing responsiveness to changes in demand under changing market conditions and linking business strategies to operational execution. The MES now provides the foundation to support other initiatives such as Advanced Planning and Scheduling (APS). OneSteel Whyalla won Exporter of the Year in the Large Advanced Manufacturer category in the 2008 Business SA Export Awards.