polr Projects

Our extensive industry experience and proven expertise in systems development, business improvement, system integration and production analysis has facilitated the successful implementation of many projects. A few success stories have been outlined below.

Blend compliance

Audience

Existing Productive Partner

Problem

An existing Productive Partner was experiencing ongoing challenges with multiple coal blend changes during shift, resulting in deviations between planned and actual coal types being fed through the ROM Bin. These discrepancies led to downstream compliance issues. Furthermore, out of specification products were being loaded onto trains, causing problems with shipments, and resulting in significant penalties (reported of up to $1,000,000 per event).

Solution

Intov8 were engaged to find a solution to overcome these challenges and from which, the Blend Compliance module was developed. The module is supported by:

  1. Purpose built database tables, stored procedures, and a suite of attribute settings
  2. A real-time blend option dashboard
  3. Purpose built reporting options and
  4. Triggered email notifications when new blends are identified

Result

The Blend Compliance module was ultimately successful and was implemented in March 2019.

 

Goods tracking implementation

Audience

New Productive Partner

Problem

In July 2017 Intov8 were engaged by a prospective Productive Partner to resolve their cumbersome, paper-based warehouse management processes. Before the implementation of POLR Goods Tracking, the company’s Goods Out Advice and Urgent Freight Register was spread across 20 different logbooks and spreadsheets and managed by several people at multiple sites. A significant portion of their warehouse stock was not accounted for in their existing systems and they were receiving as many as 30 calls per week, trying to locate equipment.

Solution

To address this pain point, Intov8 implemented our legacy product, Corvus Warehouse, to create ‘one source of truth,’ improve visibility and increase warehouse efficiency across multiple warehouses. The application was re-implemented in 2019 with Intov8’s latest product, POLR Goods Tracking, which seamlessly replaced our legacy system and integrated with the company’s existing software. This solution automated the Goods Out and Freight Register processes – a much-needed functionality.

Result

The result? The site recorded an estimated Return on Investment of $240,000 per year based on time savings.

Labour Utilisation Solution

Audience

Existing Productive Partner

Problem

In 2018, one of Intov8’s existing Productive Partners proposed a labour utilisation improvement project. Intov8 needed to integrate to the site’s access management system for the purposes of tracking and measuring the time contractors had spent on site, versus their productive operation time. The purpose of developing this integration and the subsequent reports, was so the site could manage their contractors more effectively – leave requests and approvals, assessment of productive operations and increasing resource sharing amongst crews.

Solution

A representative of the Productive Partner anticipated a predicted increase in labour utilisation of 10-20% upon the successful delivery of the project. The Labour Utilisation Project was delivered in August 2018 and then in December 2018 for all sites, with several enhancements made since then.

Result

Now, analysis and improvement of labour utilisation has become a key aspect in the management of their site contractors.

Maintenance Loss Elimination project

Audience

Existing Productive Partner

Problem

A member of the maintenance analysis and improvement team of an existing Productive Partner approached Intov8 to develop additional functionality for the POLR Resource Events module. This additional functionality intended to increase loss elimination and improve key fleet metrics such as Availability, First Failure After Services, the Percentage of Unscheduled Downtime and Mean Time Before Failure.

The existing process for recording these key fleet metrics required staff to manually input data, all stored in spreadsheets. This tiresome process meant time-sensitive decisions could not be executed efficiently. Furthermore, as the data was not visible, it was difficult for the Analysis and Improvement (A&I) team to implement more streamlined preventative maintenance for resources.

It was agreed that they required Short Interval Control (SIC), i.e. in-shift decision making capabilities for accurate, trusted, real-time data being available.

Solution

The enhancements in functionality of the POLR Resource Events Module and development of subsequent reports, significantly improved current, and upcoming maintenance processes for the company. As a result, their analysis and improvement processes were delivered more efficiently.

Load-haul dump Project

Audience

Existing Productive Partner

Problem

An existing Productive Partner engaged Intov8 when they assigned wheel loaders to move coal. On the surface this is not all together complex, but created challenges when it came to reporting and performance management. 

One machine (resource) was undertaking 3 activities: Loading, Hauling and Dumping of coal (including to and from location information). At the time, site personnel were required to manually intervene to override and correct the data for reporting and process optimisation.

Any time data needs to be inputted and maintained manually, there is opportunity for errors and omissions in the data. In this case, our client relied heavily on data integrity to make data driven business decisions, so this was not an acceptable situation.

Solution

To resolve this issue, Intov8 worked with site and corporate to develop calculations and an interface that had the capacity to track the loading unit, count loads from the unit and assign it against the correct business approved metrics. This allowed them to effectively automate reporting and undertake performance management.

Result

The successful implementation of the project concluded in April 2020 and subsequently has been rolled out to more sites. The project has had significant impact on the site’s processes ever since and provided great value.