ExeMES solution put into commercial operation at Kuzbassrazrezugol Management Company

2024: ExeMES put into commercial operation

The company OMEGALLIANCE"" on December 24, 2024 announced that the company EXEPLANT had successfully completed a project to introduce and put into operation Production Management Systems at the processing facilities of three branches of JSC Management Company "." Kuzbassrazrezugol Starting in January 2022, the project was successfully completed in October 2024.

As reported, the implementation of MES in Kuzbassrazrezugol was a necessary step, since the introduction of a modern accounting system was required to optimize the efficiency of work. The project was launched at three branches of the Company in order to standardize business processes, improve analytics and optimize management.

The project team had the following tasks:

• Unification of reporting forms and production processes between branches.
• Optimization of the quality of management decisions.
• Creating transparent accounting to provide a "Single version of the truth."
• Reduce unplanned downtime.
• Reduce analytical reporting time.
• Increase the level of execution of production tasks.
• Minimizing the impact of emergencies on the production process.

Initially, a foreign decision was considered, but after changes in the geopolitical situation in February 2022, a decision was made to switch to a domestic platform. In the period from February to September 2022, Kuzbassrazrezugol analyzed the available MES solutions on the Russian market and based on the results of the analysis, the ExeMES product developed by EXEPLANT was chosen as the platform for the project.

Expected effects from system implementation:

• Reduction of scrap at production sites.
• Increase working hours by reducing unplanned downtime.
• Improving accuracy and transparency of accounting.
• Overall performance increase.

The project began with a stage of survey and standardization of business processes and reporting forms, the results of which were target models of business processes and reporting have been developed, taking into account the peculiarities of each branch, but at the same time unified within the company. After the target process model was ready in order to test the solution architecture and hypotheses put forward, the MVP stage was launched, during which a prototype system was developed that covered the main business processes. MVP made it possible to quickly receive feedback from the business customer, apply the necessary changes and then launch iterative system development and gradual expansion of functionality. The development of the system was carried out with regular demonstrations of interim results to business customers in order to quickly obtain feedback and adapt the solution to changing conditions. The final stages of the system implementation were the stages of deployment and pilot operation. The deployment was centralized, this stage also included the configuration of integration with adjacent systems. Pilot operation was carried out individually at each site, which made it possible to effectively use the Customer's resources. This approach made it possible to take into account all the needs of the Customer's business and quickly adapt to changes in business processes.

{{quote 'author
= noted Konstantin Zaytsev, Deputy Director for Budgeting and Analytics' The MES project helped us identify the lagging zones in the organization of coal movement and processing processes, identify the missing "links" in the technical equipment of processing plants for optimization of efficiency and automation of our production. This tool requires effort from both the integrator and us system owners. But the result is worth the effort - we have the opportunity to constantly improve our production and flexibly adapt it to external factors. "}}

As of December 2024, MES is used by about 600 employees at the enterprises of Kuzbassrazrezugol Management Company.

2022: Completion of the second phase of the Russian MES development and implementation project

The company ExePlant began a development and implementation project MES at three sites "" in Kuzbassrazrezugol January 2022. Initially, the implementation of the project was expected at the decision of foreign companies. After geopolitical the situation changed world in February 2022, the solution developer left. market of the Russian Federation ExePlant, together with the customer, began to search for alternative solutions in the market Russian. This was announced on January 17, 2023 in the Group. OMEGALLIANCE

Despite the vendor's departure, the project team did not stop work and, in parallel with the analysis of the solution market, carried out work on surveying production sites, analyzing and standardizing business processes and reporting forms. In December 2022, the 2 stage of the project was completed, as a result of which the model of processes to be, the album of reporting forms, the platform for the project implementation was selected and the technical assignment for the implementation of the system using domestic software solutions was developed in detail.

Market analysis of available solutions, comparison and selection of platform for system implementation lasted from April to September 2022. The future system was to be a complex, multi-unit integrated product. As a result of the analysis, the following toolkit for the future solution was selected:

• Data collection, storage and visualization - "CONSOM GROUP" "INCA 4.0 Digital Production";
•   ExePlant - ExeMES (project development) will be used to implement MES functions;
• Business Process Management and User Collaboration - ELMA365 Platform.

{{quote 'author=commented on the head of the digital transformation program "Kuzbassrazrezugol" Gogov Rustam Andreevich.|The project for the implementation and implementation of MES in JSC "UK" Kuzbassrazrezugol "has historically matured, since it is impossible to imagine an efficient mining enterprise without an up-to-date accounting system. At the start of the project, the company chose the most comprehensive solution. Unfortunately, the geopolitical situation has developed in such a way that it was necessary to change the implementation platform "on the go." This was a challenge for Kuzbassrazrezugol, as for the client and for the partner - ExePlant. By joint efforts, we achieved the continuation of the project, found solutions suitable for the goals and tasks on the Russian market. This situation once again confirmed the fundamental importance of choosing a reliable partner for the implementation of such large-scale projects. ExePlant has once again proved its high level of professionalism and readiness for rapid change. This project will be an advanced project in the industry. It can serve as a good example of effective import substitution,}}

The implementation project is planned to be completed in 2024. When implementing the project, it is planned to solve the following tasks:

• Unification of reporting forms and production business processes;
• Control over execution of production plans;
• Improving the quality and speed of management decisions by reducing the delay in the receipt of operational information;
• Reduction of unscheduled shutdowns and downtime of stationary equipment of coal processing facilities by recording and timely notification of unscheduled shutdowns of equipment for prompt response of personnel;
• Reduction of labor costs for reporting analytical ;
• Improvement of organizational and technical level of works performance;
• Automated accumulation and provision of information on material and technical resources;
• Reducing the impact of abnormal and emergency situations on the production process by reducing the time spent on detecting and eliminating them.

Despite all the force majeure circumstances, the company is grateful to the Kuzbassrazrezugol team for their professionalism and faith in this project, as well as in ExePlant. This is a project to build a multi-purpose production management system created on Russian components. An alternative to Western solutions was found, including through the development of its own software, based on the experience gained over all these years. The main task is to prove the effectiveness of the systems and finish the project on time, stated Yuri Kereynik, executive director of ExePlant.