“Almalyk MMC” JSC is a diversified industrial enterprise that unites dozens of subdivisions. Along with the main production facilities, it also includes auxiliary services, the work of which, at first glance, is not visible, but at the same time much depends on how timely it is implemented. One of them is the Production Automation Department (PAD), which was formed on February 1, 2012.

At that time, the PAD consisted of the Central Laboratory of Automation and Geophysics, Information and Communication Technologies Department, Technical Security Systems Service, Communication Shop, and Information Service.

PAD was created in order to solve the problems of automation of technological processes, optimum production management, development of network systems, radio and telephone communications systems, increasing the efficiency of management and responsibility for the above tasks.

Today, the DAP is a communications shop, information technology service, department of regulatory and reference information, and automated process control system service.

The main tasks of our department are the development and implementation of control means and automation systems for AMMC subdivisions taking into account the specific requirements of production in order to increase productivity and improve working conditions; implementation and development of modern computer equipment, communication means, advanced information technologies, modern methods and means of information processing; organization of repair of technological control devices and automation means; organization of repair and maintenance of computer and office equipment; organization of work on radiation control and radiation safety checks in the structural subdivisions of the plant in accordance with sanitary rules and standards of radiation safety; participation in the formation and implementation of information policy determined by the management of AMMC.

To date, the DAP forces implemented and maintained 17 enterprise automated process control systems, 50 local control systems in the shops, more than fifty information systems and specialized software, our team maintains more than 70 thousand instruments of I&C, over 400 units of weighing equipment of various types, more than 4000 personal computers and office equipment, over 1600 radios, 45 telephone exchanges with a capacity of about 10000 subscribers with the length of communication lines exceeding 450 km. And all this is the responsibility of 300 specialists.

“Almalyk MMC” JSC successfully operates an extensive infrastructure of means of communication, information technologies and communications, means of automated process control system, dozens of information systems are operated, most of which are developed and maintained by the programmers of DAP. Among them are the system to optimize the process of ore delivery from the Kalmakyr mine to the copper concentration plant, the transport monitoring and fuel accounting system, accounting of utility payments at the mill, management of railway transportation processes of ore from the Sary-Cheku open pit and slag from the copper smeltery, control of the operation of technological transport of Utility Vehicles Department, etc.

All subdivisions of the plant located within the boundaries of Almalyk are connected to the corporate network based on fiber-optic communication lines. At the same time, the data transfer rate has increased 500 times in the last 5 years: from 2 Mbit/s to 1000 Mbit/s. Remote subdivisions are also connected to the corporate network - Angren mine management, Chadak mine management, Djizzak cement plant, Angren pipe works, Research and Production Association for Production of Rare Metals and Hard Alloys, zinc plant, Explosives Factory, Sherabad cement plant, Handiza mine management. Internet connection speed of AMMC specialists is 100 Mb/s. The server room of “Almalyk MMC” JSC was modernized, after which the speed of data processing increased by 5 times, and the volume of data storage by 7 times.

Our programmers have developed internal electronic document management programs. Support of such departmental information systems as “Personnel Management”, “Accounting”, “Financial Accounting”, Automated logistics management system, “Sales Management”. A computer-aided design system (CAD) has been implemented; specialists of the manufacturing site, CMRP, Design Bureau and DAP are provided with modern graphstations with specialized software and office equipment, as well as a 3D-scanner. Mining and geological software (DataMINE) was introduced to improve the efficiency of work on the calculation of reserves and preparation of inferred resources at the production and exploration works. The system allowed to organize the creation of specialized databases, with the possibility of constructing a 3D model, which gives a visual representation for specialists in the future direction of the development of mining. The system “Management of Ore Transportation Processes to Concentrators and Copper Smelters” was put into commercial operation, which allows monitoring and analysis of the work of all services involved in the production process. DataShed\ LogChief software for calculating reserves of base and precious metals at AMMC deposits according to the JORC Code was put into operation. A NEXTEDGE (Kenwood) trunking radio base station was put into commercial operation. Modern IP-PBXs are being put into commercial operation.

Consistent work on digitalization of production and implementation of the latest technical solutions to automate business processes and production tasks is currently underway. The implementation of an automated control system for the “Karier” mining transport complex at the Kalmakyr and Yoshlik I deposits is relevant to production. It will allow on-line control of the work of all mining equipment with the provision of operational information on the implementation of mining forecasts. An automated dispatcher control system “Gorny Dispetcher” is being introduced to control the work of personnel in the underground mines of “Almalyk Mining and Metallurgical Company” JSC. The project is now being implemented at the Kyzyl Alma and Razvedochnaya mines of the Angren mine management, and in the future the system will be used at all mines of the combine. Work continues on the implementation and modernization of automation systems for AMMC’s production divisions using state-of-the-art controller technology. The introduction of an automated information system of accounting, financial accounting and data consolidation of “Almalyk MMC” JSC with further integration into a unified ERP system of the plant is a requirement of the time.

To date, the republic pays special attention to the development of information technology and communications. Digital technology allows us to find new ways to increase productivity, cope with changes in the industry and improve business operations. According to analytical estimates, with the right approach to digitalization, mining and metallurgical companies can achieve impressive results: to increase profits by up to 15%; to increase production volumes by reducing equipment downtime by up to 15%; to speed up design and production processes by 100-150%; to reduce the cost of field tests through digital twins and visual modeling tools by 50-70%; to reduce costs throughout the supply chain management cycle (increase transparency of operations) by 20-30%; to optimize costs and to reduce the cost of production; and to improve the quality of the supply chain.

Thus, the digital transformation of the plant in the long term will significantly determine the competitiveness of our products. Therefore, the team of the Production Automation Department has a lot of interesting and necessary work ahead of it.

I would like to take this opportunity to congratulate the workers of DAP on their first anniversary and wish them health, longevity, happiness, and achievement of their goals!

Valiyor IRISMETOV,

Deputy Head of DAP