Today, digitization is being widely implemented in management and technological production processes in all structural divisions of the Almalyc Mining and Metallurgical Complex. As a result, high labor efficiency is achieved.

We will analyze the work done in the field in January-August of this year. In particular, a road map for the digital transformation of the complex in 2022-2026 was developed, and work on 25 of more than 50 projects planned for this year was completed.

“Directum RX” electronic document exchange system saves the paper and time

Electronic document exchange system "Directum RX" in order to increase the efficiency of the management system and digitize the business process, reduce the work with paper documents in the management process, quickly deliver tasks to the executors of the implementation of the decisions of the President and the Government of the Republic of Uzbekistan and monitor their implementation online was introduced. The system fully covered departments of the executive apparatus and all enterprises (including Surkhondarya and Namangan regions and the cities of Almalyk and Angren). This made it possible to reduce the turnover of paper documents in the Complex by 70%. Measures are being taken to reach 100% of this task by the end of 2022.

“Procurement and warehouse management” electronic system optimizes the processes to 25 percent.

In July of this year, the electronic system " Procurement and warehouse management" was launched on the 1C:ERP platform to increase the efficiency and transparency of the procurement system and to digitally control the stock of goods in warehouses. As a result, it became the basis for realistic formation of annual orders for raw materials, equipment, spare parts and other goods necessary for production needs. This made it possible to optimize the processes in the field by 25 percent, reduce the remaining goods and material assets in warehouses to 15 percent, and make it possible to target the financial resources that go to it.

Miners resource report - based on world standards

In addition, in cooperation with "SRK Consulting" company (Great Britain), a total of 2,478 geological documents prepared in 1930-2021, data on wells drilled with a length of 874 thousand pogonometers were digitized, and their single electronic database "Datashed" and Created using Logchief (Australia) software. As a result, the work with geological materials has been accelerated several dozen times, and mineral resource reporting has been launched based on the JORC code, which is in line with the world standard and required by investors.

10 tons of paper or 2 million sheets are saved in 1 year

Control of entry and exit to the Complexd facilities "E-Permit", provision of electronic passes "E-Talon", financial and accounting monthly electronic reports, accounting of utilities "Communal Billing", salary information of employees "Monthly Bot" and medical examination "Electronic medical card" systems were introduced.

In return for the implementation of these projects, more than 10 tons of paper (or 2 million sheets) were saved per year, and labor resources and time spent on operations related to paper documents were reduced to a minimum level.

“Wialon” system has saved 117 billion sum in 8 month

In order to automate production processes and use modern information systems, "GPS" monitoring was implemented on a total of 1,700 vehicles, and the "Wialon" fuel control system was improved. As a result, the full analysis of the working process of vehicles and the efficiency of their use have been improved, and more than 9350 tons of fuel (117 billion soums) have been saved in the 8 months of this year.

Efficiency of “PI System”

"PI System" (Plant Information System) was introduced at the copper beneficiation factory, due to the consolidation and visualization of information in the technological process and the online control of devices through more than 10,000 tags, the time of quick decision-making was reduced by 2 times, the efficiency of the equipment was increased by 5 percent.

Service time reduced by 2 times

In the control system of fuel and lubricants, the works of allowing refueling of motor vehicles through ID cards, monitoring daily limits and keeping reports in electronic format have been completed. As a result, annual fuel costs were reduced by 3-4 percent, service time at gas stations was reduced by 2 times, and paper reporting was abandoned. For information, 75,000 tons of fuel are poured into 1,700 vehicles per year at the Complex.

Future plans

Work on 22 more projects will be completed by the end of this year. In particular, the mining dispatch system will be launched in the Angren mining department, and it will create an opportunity to monitor the work of more than 44 vehicles and technical equipment in the mines, as well as to protect 759 employees and provide them with quality communication.

In the distance education system, online training of employees of the Complex without leaving the main workplace, improvement of skills and qualifications, training of personnel in the field based on a set of specially developed programs, and monitoring of the level of knowledge will be established. As a result, 1,500 employees are trained per year without leaving the workplace and costs are reduced by 15 percent.

Railway maintenance and repair management system, based on RFID technology, accurately takes into account the distance traveled by each railway vehicle, automatically plans maintenance and repairs, and provides them with high-quality expenses will be reduced by 10 percent or 7.3 billion soums per year due to implementation.

An automated water supply management system of the copper beneficiation plant was introduced, technical water consumption was optimized, its rational use was established, and 5.4 million tons of water or 2.4 billion soums were saved per year.

In order to improve the skills of employees, a training laboratory will be established at the Almalyk branch of MTTU MISiS in cooperation with "SIEMENS" (Germany) and "AVEVA" (Great Britain) companies, training and certification of personnel at the level of international standards will be launched.

More than 10 memoranda of understanding on digitization have been signed with "SIEMENS" and "SAP" (Germany), "AVEVA" and "Datamine" (UK), "Schneider Electric" (France) and other international companies. The initiatives implemented by mining metallurgical companies in the field of digitization were studied. A number of priority projects for the digital transformation of the Almalyk Mining and Metallurgical Complex have been identified.

In particular, in order to fully automate finance, treasury, production and trade activities, as well as business processes, and to reduce the cost of products by 3-4 percent, the SAP ERP system will be introduced based on the concept developed in cooperation with the consulting company "KPMG".

For the purpose of real-time control and quick management of production processes, the useful working efficiency of the equipment will be increased by 5-6 percent, and unplanned downtime will be reduced by 15 percent in exchange for launching the MES system. This, in turn, makes it possible to increase the volume of product production and ensure its quality.

Due to the implementation of the operational management system in the "Kalmoqqir" and "Yoshlik I" mines, the volume of rock transportation will increase by 10 percent, the cost of using mining equipment will be reduced by 5-6 percent, and fuel consumption will be reduced by 9 percent.

I can safely say that now we are working hard to improve the efficiency of mining and metallurgical network using modern information and communication technologies in performance of the tasks mentioned in the road map of digital transformation during 2022-2026 years.

Abdulla Azizov,

Deputy chairman for Digitalization of the Board of AMMC