In the mining sector, the performance and lifecycle of assets, especially large-scale equipment, are critical elements for operational success. The Operational Readiness (OR) phase is essential to ensure that new or upgraded assets are ready to operate effectively from day one, without surprises that could compromise production. But what exactly does Operational Readiness involve, and why is it so crucial for your project?
What is Operational Readiness?
Simply put, Operational Readiness ensures that everything is in place for assets to function without interruptions. It is the structured process of preparing to successfully transition from the project phase to the operational phase. This involves ensuring that all technical documentation, spare parts, knowledge transfer, training, and support systems are available and functioning properly to minimise downtime and operational risks.
In the mining sector, where equipment reliability is paramount, well-executed Operational Readiness can be the difference between success and failure. In addition to preparing the physical infrastructure, Operational Readiness ensures that operational teams have the knowledge and skills needed to safely and efficiently operate and maintain the equipment.
What is Involved in Operational Readiness?
Generally, Operational Readiness for a new plant includes:
Cataloguing of all relevant documentation to the asset/s.
Development of an asset hierarchy.
FMECA validation, including review of corrective and preventative actions.
Operational analysis, to ensure the strategy can be implemented within your organisation.
Maintenance work instruction development.
Critical and material spares development.
Consumables stock development.
How is this Achieved?
Effective Operational Readiness covers several key areas:
Complete Technical Documentation: One of the main components of successful Operational Readiness is ensuring that all technical documentation, such as drawings, operation manuals, spare parts lists, and commissioning parameters, are available and understood by operational teams. Failures in delivering or organising these documents can lead to misunderstandings and, eventually, unnecessary downtime, impacting the asset's productivity.
Knowledge Transfer and Training: For the operational team to take control of new assets, there needs to be a smooth knowledge transition between the teams involved throughout the full asset lifecycle. This includes everything from preventive and corrective maintenance strategies to detailed work instructions, ensuring that the team can perform maintenance and operate the assets safely and efficiently.
Systems and Process Integration (SAP): Effective management of master data, particularly in ERP systems like SAP, is crucial to ensure that all asset information is up-to-date and easily accessible. This includes everything from creating functional locations to cataloguing spare parts and defining maintenance strategies.
Asset and Spare Parts Criticality Assessment: Determining the criticality of each asset and spare part is essential to mitigate the risk of catastrophic failures. A well-executed Operational Readiness plan identifies the most critical parts and ensures they are available when needed.
Why is Operational Readiness Important?
In mining operations, where assets often work under extreme conditions, failing to implement proper Operational Readiness can lead to expensive downtime, safety risks, and project delays. Operational Readiness ensures a smooth transition from the development stage to full operational use, minimising risks and maximising asset performance and lifecycle. Additionally, it prevents costly last-minute scrambles for documentation or spare parts, setting your team up for long-term success.
When Operational Readiness is well executed, it ensures that:
Equipment is efficiently brought into operation from day one, without major interruptions.
Downtime is minimised, as teams are prepared to respond to failures with the correct documentation and spare parts.
The asset’s lifecycle is maximised, allowing assets to meet or exceed their expected lifespan, resulting in a higher ROI.
The Risks of Poor Operational Readiness
Imagine the following scenario: a major mining project where equipment delivery was completed without proper spare parts cataloguing or data configuration in the SAP system. When the equipment failed, maintenance teams faced delays in identifying and ordering the correct parts. This downtime cost millions in lost productivity and repairs.
This situation could have been avoided with a more structured approach to Operational Readiness, ensuring the team had all necessary resources from the start of operations.
The Opportunities of Well-Executed Operational Readiness
Now, imagine a mining company that implemented a new crushing system, exemplifying the benefits of a well-structured Operational Readiness. Before commissioning, the company ensured all master data in SAP was properly configured, spare parts were catalogued, and the operational team received comprehensive training. As a result, the system was brought into operation smoothly, reaching its maximum capacity without unexpected downtime. This demonstrated a seamless transition from project to operation, reducing risks and maximising asset performance.
A well-executed Operational Readiness not only ensures that your assets enter operation without issues but also lays the foundation for an efficient and productive lifecycle.
With a strategic and well-structured approach, your operation will be prepared to face industry challenges and capitalise on every success opportunity. Lead Asset Management (LAM) is by your side to ensure that your projects make a smooth transition throughout the asset's full lifecycle, reducing risks and promoting efficient asset management.
When properly planned, Operational Readiness becomes a competitive advantage, enabling your operation to reach peak efficiency and secure a successful future.
How LAM Can Help
At Lead Asset Management, we assist you in developing detailed Operational Readiness plans that ensure your assets are prepared for operational use from day one. Our expertise in asset management systems, such as SAP, allows us to work with you to manage master data, catalogue spare parts, and perform criticality assessments. We help ensure that your team has the knowledge and tools they need to operate and maintain assets seamlessly.
A well-planned Operational Readiness strategy mitigates the risks of delays, unexpected downtimes, and inefficient operations. By partnering with LAM, you can trust that your assets will transition smoothly into operation, helping you achieve long-term success and operational efficiency.