August 08, 2024
Laboratory Digitalization at Birla Copper Dahej
Birla Copper Dahej, a division of Hindalco Industries Limited, operates one of the
world’s largest single-location custom copper smelters, founded in 1998 in Dahej, Gujarat.
Despite its robust infrastructure and ISO certifications, the facility encountered significant
hurdles due to manual laboratory methods, leading to inefficiencies, increased workloads, and
data management challenges. Recognizing the need for modernization, Birla Copper Dahej took
inspiration from successful laboratory digitization initiatives by Revol Process Solutions at other
Hindalco locations. After thorough evaluation, they chose to implement Revol LIMS, a 100%
web-based Laboratory Information Management System, to transform their operations.
The implementation of Revol LIMS marked a pivotal step towards enhancing data
visibility, minimizing manual intervention, boosting productivity, improving traceability, and
ensuring safety compliance. The system automated sample management, streamlined repeated
analyses, and optimized shift management, significantly reducing employee workload and
increasing plant efficiency. Post-installation, Birla Copper Dahej has witnessed remarkable
advancements in operational efficiency, industry accreditations, productivity, data security, and
quality assurance. Revol LIMS has been instrumental in digitalizing laboratory operations,
enabling Birla Copper Dahej to achieve its operational and quality excellence goals, aligning
with their vision of sustainable growth and embracing Industry 4.0.
Situated in the Bharuch district of Gujarat, near Dahej, the complex includes a jetty,
refineries, rod plants, captive power plants, and copper smelters. The plant operates continuously
and is supported by captive power plants, oxygen plants, and other by-product plants. The
facility produces platinum, selenium, silver, and gold at various precious metal recovery facilities
and is accredited by OHSAS 18001, ISO 9001, and ISO 14001, and is listed on the London
Metal Exchange.
Quality concern is crucial for Birla Copper Dahej, which has set self-imposed
environmental targets to ensure sustainability. Copper concentrate, the main component of the
copper manufacturing process, is imported via the plant's jetty, operated by Dahej Harbour and
Infrastructure Limited, with a capacity to handle four million tonnes of cargo annually. Initially
designed to produce 100,000 TPA, the production capacity has increased to meet the growing
demand for copper, now reaching 500,000 TPA.
The facility generates more than 800 testing samples daily across 7 labs staffed by 59 lab
analysts. Primary products include continuous cast copper rods and copper cathodes,besides
gold, silver, phosphoric and sulfuric acid, diammonium phosphate, phospho gypsum, and copper
slag. Hindalco is the sole producer of copper rod with a 29.6 mm diameter used for railway
electrification in India.
Despite its world-class infrastructure and high-performance metrics, Birla Copper Dahej
was hampered by several operational challenges that significantly impacted its efficiency and
accuracy. These challenges include:
Manual Data Management:
With the facility generating over 800 testing
samples daily, manually recording and processing this data became a significant
burden, impacting potential productivity gains that had to be achieved.
Traceability of Results:
To ensure high quality and market trust, Birla Copper
Dahej's import and export operations required precise and traceable reporting.
Manual data entry in Excel was both time-consuming and error-prone, leading to
inconsistencies and unreliable outcomes.
Instrument Handling:
Given the age of operations, Birla Copper's laboratories
feature a mix of analog/manual equipment and devices with PC/RS232
connectivity. Manual sample examinations heightened the risk of measurement
errors, while managing timely calibrations, scheduling services, and reporting
available equipment was complex, ultimately compromising overall quality.
Shift Management:
Coordinating and managing three shifts presented a
formidable challenge. The absence of real-time tracking and oversight escalated
employee workloads, reduced efficiency, and hindered operational visibility to the
management, impacting operational flow.
Data Access:
Accessing generated results manually was labor-intensive and
time-consuming, causing workflow disruptions and delaying crucial
decision-making processes.
Revol LIMS is a 100% , web-based laboratory information management system
specifically tailored to the mining and metals sector, which can be deployed on client servers and
accessed across their enterprise. The Mobile Apps allow offline entries from the remote locations
with network hassles, these entries are automatically updated once connected to the network.
Process Optimization:
Revol LIMS automates and simplifies laboratory
workflows, tasks, and resource management. By strategically assigning and
optimizing laboratory personnel, tools, and supplies, Revol LIMS enhances data
analysis and utilization, leading to more efficient and streamlined operations.
Integration Capabilities:
Revol LIMS supports seamless data integration with
other software systems using protocols such as REST API, etc. This enables
efficient data sharing and collaboration across departments, including sales,
quality, and production, ensuring a cohesive and integrated approach to
operational excellence.
Traceability:
With comprehensive tracking and management of samples from
collection to reporting, Revol LIMS ensures controlled movements, conditions,
quantities, and storage locations. This significantly enhances overall traceability
and accountability, critical for maintaining high standards in laboratory
operations.
Operational Excellence:
Revol LIMS boosts productivity and plant visibility
through comprehensive dashboards and automated workflows. Its real-time
monitoring and management capabilities significantly enhance operational control
and efficiency, propelling Birla Copper Dahej towards sustainable operational
excellence and Industry 4.0.
Faced with operational challenges and the need for a more efficient, reliable system to manage laboratory operations, Birla Copper Management embarked on a search for a solution that could fully monitor and systematize their manual processes and automate data visibility across the value chain. They identified Revol LIMS as the ideal choice based on its comprehensive features and rational TCO.
Revol LIMS is a 100% web-based laboratory information management system, which
was implemented to fully digitize and manage all laboratory data.
Reduced Manual Error:
Reduced Manual Error: Automation of data retrieval and processing
significantly reduced the likelihood of human errors, saving time and enhancing
accuracy.
Reporting Transparency:
The system simplified the gathering and recording of
sample findings, ensuring accurate and reliable results for import and export
processes by bringing in traceability from raw material to finished product.
Improved Shift Management:
With scheduling and sample workflow
management efficiency managing samples and reporting across shifts has become
easier.
Enhanced Quality Management:
The comprehensive quality management
system provided by Revol LIMS facilitated transparency in operations,
traceability in reporting, feedback management implementing CAPA, improved
audit preparedness (internal and external) and monitoring proficiency of lab
personnel through learning management.
The implementation of Revol LIMS brought about significant improvements in Birla Copper Dahej's operations, including:
The integration of Revol LIMS at Birla Copper Dahej marked a significant leap forward in laboratory operations. Thanks to comprehensive training and support from Revol Process Solutions, the system was swiftly embraced. Revol LIMS effectively curtailed human errors and inefficiencies, elevating accuracy and reliability across lab processes. Automated scheduling and secure data storage not only bolstered management oversight but also amplified operational transparency. This streamlined shift management, reducing employee stress and enhancing workflow efficiency. Through digitized processes and enhanced data accessibility, productivity and operational efficiency experienced a notable upsurge. The rich array of dashboards furnished by Revol LIMS offer real-time insights to management, facilitating astute decision-making and operational mastery. This drives Birla Copper Dahej towards a paradigm of traceable, transparent, and sustainable laboratory operations.
The implementation of Revol LIMS at Birla Copper Dahej marks a significant leap
towards sustainable operational excellence and Industry 4.0 integration. By digitizing laboratory
operations, streamlining workflows, and enhancing data visibility, Birla Copper Dahej has not
only overcome its operational challenges but has also achieved remarkable improvements in
efficiency, productivity, and quality assurance. This transformative step underscores Birla
Copper Dahej's commitment to innovation, sustainability, and delivering world-class products.
Embracing 100% web-based solutions like Revol LIMS promoted the Birla Copper Dahej
facility to continued growth and success in the competitive global market.
Unlock the full potential of your laboratory and operational processes with Revol LIMS.
Say goodbye to errors, inefficiencies and excessive workloads. Contact www.revollims.com and
embark on your journey towards enhanced efficiency, quality, and operational excellence.