IntelliPERMIT at Metalloys –
a decade later
Karl Frenz
Account Manager
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Agenda
• Metalloys site - background
• Key contributors to success
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Product
Client contributions
Vendor contributions
Communication and teamwork
• The road ahead
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Samancor Metalloys
• Samancor Manganese is the world’s largest integrated producer of
manganese.
• 60 per cent owned and operated by BHP Billiton.
• Metalloys is located near Meyerton
• It has four electric furnaces, three of which are amongst the largest in
the world.
• Metalloys produces high-carbon and medium-carbon
ferromanganese.
• Manganese ore comes from Hozatel Manganese Mines (Wessels and
Mamatwan).
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IntelliPERMIT at Metalloys
• Samancor Metalloys - one of ApplyIT’s first IntelliPERMIT clients.
• Implementation Project
• West Plant: IntelliPERMIT project kickoff - 4 October 2004, go-live - 24 November
2004.
• First week of operation - some 350 permits by 130 contractors and employees.
• North and South Plants: completed by July 2005.
• Materials Handling, Engineering Services, Labs, SHEQ, Admin: completed by
September 2005.
• Now, 9 years later, the stats are as follows:
• 300,000 permits, 3 million electronic signatures
• 9000 unique users over this period.
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IntelliPERMIT at Metalloys
• 10 Units, 420 Areas
• Responsibilities of System Administrators
• About 10 administrators
• Manage users and contractors, manage competencies, train end users, make
configuration changes, etc
• Responsibilities of dedicated Permit Issuers
• At least 8 dedicated issuers
• Initiate permits, apply/confirm lock-outs/isolations, manage the permit life cycle, add
users, allocate competencies
• Multiple permit issue stations to manage volume of transactions
• Plan to fully implement isolation procedure management, started at West Plant,
waiting for upgrade
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IntelliPERMIT at Metalloys
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IntelliPERMIT at Metalloys
• BHP Billiton has an excellent safety record
• Implementation received a BHP Billiton award in 2005
• In recent audit, recommended as “benchmark for PTW”
• Considered to be mission-critical at Metalloys
• “The core of our Risk Control program” – Hannelie Jordaan
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Key contributors to long term
success
• Product
• Client contributions
• Vendor contributions
• Communication and team work
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Product
• A product that properly addresses the client’s business needs
• A user-friendly, easy to use system
• Ability/flexibility to incorporate new client requirements - continuous
improvement
• Biometrics introduced for the first time – passwords not secure
enough
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Client contributions
• A safety culture
• Top management commitment from outset
• Middle management buy-in
• Motivated super-users
• A team approach
• Properly documented SOP’s/business rules
• External inputs (regular audits by peer organisations)
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Vendor contributions
• A successful initial implementation
• Focus on long term, mutually beneficial relationships
• A solid support model
• Properly functioning Help desk
• Regular health checks – business and technical focus
• On-going training/coaching
• Committed, knowledgeable support consultants
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Communication and Teamwork
• Relationships are key, we work with people
• Formal communication important
• Forums
• Account management
• Help-desk
• Informal communication – do not under-estimate
• A team effort – no “us and them”
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The Road Ahead
• IntelliPERMIT approved for BHP Billiton 1Desktop, subject to final
client testing
• Continue providing world class software
• Cannot ever rest on our laurels
• Incorporate appropriate technologies into product offering (cloud, mobile,
etc)
• Listen to clients
• Never take clients for granted!
• Continue supporting to best of our ability
• Improve software, implementation methodologies, training and support
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Acknowledgements
• Thanks to ( at least) the following people:
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Phillip Hechter
Steynberg Janse van Rensburg
Renier Henning
Andries Smith
Hannelie Jordaan
Scott Bredin
Dr Tim Wickins
Shannon Wiesinger
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Thank you!
Questions ?
Karl Frenz
karl.frenz@adaptit.co.za
083 567 7270
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