Implementation of Revol LIMS at Hindalco Mahan Coal Plant

Executive Summary

Hindalco Industries (formerly known as Hindustan Aluminium Corporation Limited) is Asia’s largest fully integrated aluminium producer and a prominent leader in both aluminium production and downstream value-added products in India. As a subsidiary of the Aditya Birla Group, Hindalco holds the distinction of being the world’s largest aluminium rolling company. The company’s operations include bauxite mining, alumina refining, coal mining, captive power generation, aluminium smelting, rolling, extrusion, and foil production, with multiple facilities across India.

The company’s management has strategically located its facilities near key raw material sources while maintaining a strong presence in markets with high demand, contributing to enhanced profit margins. Hindalco believes that leveraging advanced technology not only reduces operational costs but also allows for the production of superior, customized products. By upgrading its technologies, Hindalco has been able to achieve higher plant utilization, greater efficiency, and increased revenue.

As part of its journey toward Industry 4.0, Hindalco is progressively digitizing various aspects of its operations. A crucial part of this transformation is the digitalization of its laboratories, for which Hindalco selected Revol Process Solutions Pvt. Ltd. (Revol) to implement their flagship product, Revol LIMS (Laboratory Information Management Solution). The aim is to streamline laboratory processes, from sample intake to reporting, using a unified system that tracks tasks and approvals.

Revol successfully integrated key features like sample management, workflow automation, instrument integration, reporting, CoA forms, and ERP connectivity. Hindalco’s laboratory managers were seeking a solution that could be easily adopted with minimal resistance from users. The successful deployment of the system within the specified timeline has established Revol as a preferred partner for laboratory digitalization.

Background

Hindalco’s Mahan Coal testing are a vital component of the operations of the company, supplying coal to its thermal power plants. The quality of coal extracted has a direct relationship with the efficiency of the plants, and strict quality testing is necessary for each batch of coal extracted. The laboratory at Mahan Plant however was experiencing some problems, including:

Manual Data Entry: Data entry was mostly manual, resulting in errors, delays, and inefficiencies.

Data Tracking and Reporting: Inability to access test results and reports in real-time, making it hard to monitor performance and analyze data in a timely manner.

Compliance and Standards: Regulatory compliance and conformity to industry standards necessitated precise and timely reporting, which was hampered by the current processes.

To address these issues and increase overall operational effectiveness, Hindalco approached Revol LIMS to automate laboratory operations and manage coal quality testing better.

Project Objectives

The main objectives behind the deployment of Revol LIMS in Hindalco Mahan Coal Plant were:

Data Management Automation: Automate data collection, analysis, and reporting by automating processes.

Real-Time Access to Data: Give real-time access to test results and analytics to lab technicians, managers, and other stakeholders.

Improve Accuracy: Reduce human errors by using automated data entry and analysis.

Regulatory Compliance: Make the lab’s data management practices align with industry standards and regulatory needs like ISO/IEC 17025.

Operational Efficiency: Improve the turnaround time for quality testing and reporting, increasing overall productivity.

The Challenges

Hindalco, a leading player in the mining and metals sector and a part of the Aditya Birla Group, operates numerous sites, many of which are in remote locations. Building robust infrastructure to ensure smooth operations has been a top priority. Despite efforts to introduce digitization, the laboratories at these sites continued to face inefficiencies and fragmented data management. Previous attempts to digitize laboratory operations, whether through internal solutions or third-party vendors, had failed due to scalability challenges and the creation of data silos, which limited visibility and drove up costs.

The laboratory management encountered several difficulties, including errors in sample collection, improper identification of samples, tracking issues, and a heavy dependence on manual data entry. These challenges exacerbated operational inefficiencies, particularly as skilled team members were spending excessive time on repetitive tasks instead of focusing on more complex, value-added work. Moreover, the IT team had concerns regarding the integration of Revol LIMS with their existing CSCTS Server.

Solution

Revol LIMS was chosen for its ability to support complex laboratory procedures as well as integrate well with Hindalco’s current IT infrastructure. The LIMS solution offered the following functionalities:

Sample Tracking: The system enabled effective tracking of coal samples from collection to analysis, maintaining proper chain-of-custody.

Data Integration: Revol LIMS interfaced with existing equipment to capture real-time test results from instruments used to analyze coal.

Automated Reporting: Test results were automatically summarized in pre-designed report formats, ready for viewing and submission.

Customizable Workflow: The system was designed according to the exact requirements of coal testing, permitting customizable workflows based on the range of tests necessary (e.g., ash content, sulfur content, calorific value, etc.

Audit Trails & Compliance: Revol LIMS made sure that all the data was captured and stored securely, giving an auditable trail for compliance with industry standards and regulations.

Mobile Access: Test results and data could be accessed by lab technicians from mobiles, enabling quick decision-making and problem-solving.

Implementation Process

The Revol project execution team followed a structured approach to implement the solution:

Kick-Off Meeting: The project teams from Hindalco and Revol held an initial meeting to define key personnel, establish a communication plan, and agree on a schedule for regular progress updates. The required data for the LIMS system was identified and shared with Hindalco to create a Data Repository, which would serve as the system’s foundation.

GAP Analysis: Revol carried out a thorough analysis of the information flow for sample management, from data collection through to reporting and final results. This analysis helped the team pinpoint the features available in the existing product, the necessary configurations, and any customizations required to meet Hindalco’s specific needs.

Sample Workflow Development: The sample registration process at Hindalco begins at the Auger Mining Machine, controlled by the CSCTS Server, which tracks truck movements from mining sites. The Revol team spent some time developing and integrating custom plugins with the CSCTS Server to ensure smooth tracking of sample collection and compliance with Hindalco’s standard procedures.

Configuration and Customization: Based on the insights from the GAP Analysis and Workflow study, Revol’s team configured the required workflows and reports. Where necessary, custom features were developed to address specific requirements. The sample management module within Revol LIMS was set up and integrated with the CSCTS Server via the Revol API. This included adding barcode labeling for samples, instrument integrations, QMS workflow generation, and CoA report creation. Additionally, the team designed and deployed all required reporting templates.

Instrument Integration: Revol was responsible for integrating several Analytical Instruments (e.g., Bomb Calorimeter, Sulphur Analyzer, TGA) into the LIMS platform. After gathering the necessary file formats and information, Revol developed file parsing protocols to automate data extraction from the reports generated by these instruments. This automation eliminated manual data entry, minimizing the risk of transcription errors during report preparation.

Verification and Final Acceptance Testing: During the testing phase, the Revol team worked closely with Hindalco’s team to refine the system design and ensure compatibility with Hindalco’s network and requirements. Prior to final deployment, the system underwent extensive testing by Hindalco’s project management team, confirming that the system met the project’s original objectives. LIMS trainers and laboratory staff also tested the system’s features and functionality, using a checklist to ensure that all components were properly installed and operating as expected. The aim of this phase was to validate the system’s overall performance and functionality.

Training and Development: The final rollout was supported by Hindalco’s IT team to address any unforeseen issues promptly. Once the User Acceptance Testing (UAT) was completed and approved by Hindalco’s project team, Revol organized training sessions for the remaining users at the Hindalco site. As the users transitioned from manual processes to the Revol LIMS system, they became familiar with its features and functions. By the end of March 2021, the Hindalco evaluation team at the Jharsuguda site successfully completed the final acceptance testing and formally signed off on the LIMS implementation project.

Results and Benefits

Revol LIMS implementation at Hindalco Mahan Coal Mines provided a number of key benefits:

Better Data Accuracy: Through automation of data collection and reporting, the likelihood of human errors was considerably decreased, leading to more accurate test results.

Increased Efficiency: The automation of workflows and ready access to data led to reduced turnaround time for quality testing and reporting.

Improved Compliance: Revol LIMS allowed Hindalco to ensure compliance with regulatory requirements by offering secure and auditable management of data.

Improved Decision-Making: Ready access to test results and analytics enabled managers to take well-informed decisions in a timely manner, enhancing operational efficiency.

Cost Savings: The elimination of manual steps and errors resulted in cost savings in labor, rework, and delays.

Conclusion

The deployment of Revol LIMS at Hindalco Mahan Plant effectively resolved the laboratory’s issues and introduced significant operational efficiency, data accuracy, and compliance improvements. Through automation of key processes, Hindalco not only improved the performance of its coal testing laboratory but also facilitated faster, more accurate decision-making for its entire mining operation.

The success of this project demonstrated the power of combining modern technology such as Revol LIMS to tackle complex issues in businesses such as mining, where efficiency in operations and compliance with regulation are a priority. Hindalco’s choice of implementing this technology has paved the way for sustainable expansion and enhancement in testing processes for coal quality, making the company competitive and compliant in the global arena.