INTELATRAC DEVELOPMENT

IN THE PATH FOR WORLD CLASS MAINTENANCE STANDARD

CALETONES SMELTER CODELCO EL TENIENTE

Andrés Bobadilla – Reliability Engineer Chief – Codelco Teniente

Marcos Ríos – Lead Engineer – Schneider Electric

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Introducing CODELCO

CODELCO Operations

2013 Codelco Main Indicators

Introducing El Teniente Division

Mine Type Underground & Open Pit mining

Operation From 1905

Location Rancagua, Región del Libertador General

Bernardo O'Higgins

Main products Anodic copper bars, Copper and

Molybdenum Concentrate

Production 450.390 RMT/Year

Workmanship 5.064 (own personel)

El Teniente Division

Caletones Smelter

Fusion Reactors 2

Copper Smelted 1.400.000 TPY

Main Product Anodic

Copper/H2SO4

Copper/year 340.000 RTY

Sulphuric Acid 1.360.000 TPY

A little bit of history…

A little bit of history…

Technology Evolution…

How maintenance fits to new age

“We believe that strengthening tools for maintenance people is to find and solve early problems, it’s a key part of the success”

At this time, production planning is everyday closer or over design rate, requiring minimum or optimized maintenance.

Just doing maintenance and improving with another techniques without a close engaging with plant reality, does not allow success.

New Challenges

2005 Was a big change with new projects on the smelter, to improve plant production.

2014 and beyond: Is another big change with several projects to improve plant production to their limit.

A tool to:

• Make maintenance (inspection) rounds, ensuring jobs are done

• Bring information closer from field to superior levels

• Have SAP integration experience

• Simplify maintenance process

• Help to feed maintenance systems with valuable information for reliability analisys

• Allow access for technical information from field

We tried with local companies, SAP, Accenture.

“During the selection process we finally chose IntelaTrac”

What we wanted from the market

After 14 months of integration development between SAP and Intelatrac, modifications and update on Intelatrac, we are now on SAP testing process, one step before to raise to SAP production mode.

What we got:

- Communication with SAP to schedule work orders

- Tool easy to use, just get the information that we need from the maintenance people

- Standarize inpections from one to another people

- Full traceability (worker, time, equipment), and not allowing advance without triggering the RFID

- Optimizing maintenance process

- Work order is closed automatically

- Confirmation is updated with manpower used and calculed automatically

- Sub work orders are created and scheduled according to their severity, programmed on the system

Implementation process

How IntelaTrac works in Codelco Teniente?

• Simple Architecture for IntelaTrac 4.2 SP2

How IntelaTrac works in Codelco Teniente?

• IntelaTrac – SAP Integration

It’s responsible to:

• Retrieve the WO List using

the status of the system

(released on SAP) and the

WO Type.

• Retrieve the details of the

WO based on the Work

Center.

• Update the WO and

Notification fields in SAP

• Update measurement points

in SAP

• Delete and deactivate

procedures in IntelaTrac and

close the WO and

Notifications associated.

• Create new revisions of the

procedure based on the

previous values.

• Update the procedure name

with the status “Scheduled”

with “-S”.

It’s responsible to keep the

Master Data between SAP and

IntelaTrac updated

• Functional Location

• Priorities

• List of Materials

• Planner group

• Activity Type

• User status

• WO Types

• Work Center

• Cause Codes

• Activity Code

• Problem Codes

Services Description

SAP Data Synchronization

It’s responsible to create

procedures dynamically on

IntelaTrac, using templates

procedures and configuration

parameters to mapping with

SAP..

It can create 2 kind of

Procedures:

• WO Planning Procedure

• WO Execution Procedure

SAP WO Execution SAP WO Integration

IntelaTrac – SAP Integration

New Work Order

Completed WO

IntelaTrac Procedure IntelaTrac Round

IntelaTrac Round Completed

Sub-WO

IntelaTrac – SAP Integration: Details

Rounds execution pictures

Lets see how it works!

Next Steps…

• Raise to SAP Production environment

• Expand to other areas and other divisions of Codelco: Currently

Codelco Radomiro Tomic

• Upgrade to IntelaTrac 4.3

• Include more functionalities in the Integration SAP-IntelaTrac:

- Include more SAP fields

- Include functionality “Notification creation”

- Improve Reports

• And more!

• System is close to start working on SAP Production enviroment

• Development process has been long, but we now that final product will be a change in the medium time on the maintenance standard and bussiness development.

• There is a long path to keep developing the system to improve capabilities

• Make it Simple is a good way to introduce the system to all levels

• It can centralize the field knowledge in only one tool.

• It can be used by operators

“See you at the Next Global Conference to show the

Final result and advance history”

Summary

Thanks

Questions?