Os processos extrativos tradicionais apresentam estágios que precisam de modernização e melhorias para permitir que as empresas mineradoras provisionem de maneira eficaz a qualidade e a quantidade de seus produtos. Tal garantia de provisão, tão difícil de sustentar devido à natureza intrínseca da incerteza geológica, pode somente ser conseguida com um aumento de eficiência nas cadeias logísticas minerais. Este trabalho demonstra os benefícios de se criar modelos de cadeias logísticas minerais existentes para identificar e compreender os pontos de criação de valor para possíveis intervenções visando melhorias. O trabalho também fornece um guia de modelagem, através de uma planilha eletrônica, permitindo aos usuários modelar quaisquer tipos de cadeias logísticas. O conhecimento do trajeto dos processos desde a extração ao consumidor final fornece uma oportunidade única para que os gerentes melhorem suas cadeias logísticas. Depois que o modelo foi criado, ele pode e deve ser melhorado. Um número técnicas e boas práticas já em uso por outros setores, mas ainda não aplicado setor mineiro são identificadas e estruturadas. Uma metodologia para a aplicação estratégica destas técnicas é então fornecida. O setor mineiro em todo mundo está sob pressão para procurar métodos para melhorar sua eficiência. Este trabalho introduz, de uma maneira inovadora, uma estratégia administrativa na mineração que se provou extremamente competitiva em outras indústrias. A questão básica abordada neste trabalho é como desenvolver uma metodologia robusta e controlada para que o setor mineiro tire proveito da filosofia enxuta, introduzindo o conceito de Lean Mining. / Traditional extractive processes present stages that need modernization and optimization for enabling mining companies to warrant the effective achievement of both product quality and quantity. Such warranty, which is difficult to sustain due to the intrinsic nature of geological uncertainty, can only be achieved through an increased efficiency in the mineral supply chain. This work demonstrates the benefits of creating models of existing mineral supply chains to identify and understand the points of value creation and places for possible improvement interventions. It also gives a modeling guide, through an electronic chart, enabling users to model any kind of supply chain. The knowledge of the process path from extraction to final consumer provides a unique opportunity for managers to improve the mineral supply chain. After the model has been created, it should and must be improved. A number of techniques and good practices already in use by other sectors but not yet applied to the mining industry are identified and structured. A methodology to strategical application of these techniques in provided. The mining industry all over the world is under pressure to look for methods to improve its efficiency. This work leads the way to an innovative managerial strategy in mining that has proved itself extremely competitive in other industries. The key issue addressed in this work is how to identify a robust and risk-controlled path for the mining industry to benefit from the lean thinking approach, introducing the concept of Lean Mining.

Os processos extrativos tradicionais apresentam estágios que precisam de modernização e melhorias para permitir que as empresas mineradoras provisionem de maneira eficaz a qualidade e a quantidade de seus produtos. Tal garantia de provisão, tão difícil de sustentar devido à natureza intrínseca da incerteza geológica, pode somente ser conseguida com um aumento de eficiência nas cadeias logísticas minerais. Este trabalho demonstra os benefícios de se criar modelos de cadeias logísticas minerais existentes para identificar e compreender os pontos de criação de valor para possíveis intervenções visando melhorias. O trabalho também fornece um guia de modelagem, através de uma planilha eletrônica, permitindo aos usuários modelar quaisquer tipos de cadeias logísticas. O conhecimento do trajeto dos processos desde a extração ao consumidor final fornece uma oportunidade única para que os gerentes melhorem suas cadeias logísticas. Depois que o modelo foi criado, ele pode e deve ser melhorado. Um número técnicas e boas práticas já em uso por outros setores, mas ainda não aplicado setor mineiro são identificadas e estruturadas. Uma metodologia para a aplicação estratégica destas técnicas é então fornecida. O setor mineiro em todo mundo está sob pressão para procurar métodos para melhorar sua eficiência. Este trabalho introduz, de uma maneira inovadora, uma estratégia administrativa na mineração que se provou extremamente competitiva em outras indústrias. A questão básica abordada neste trabalho é como desenvolver uma metodologia robusta e controlada para que o setor mineiro tire proveito da filosofia enxuta, introduzindo o conceito de Lean Mining. / Traditional extractive processes present stages that need modernization and optimization for enabling mining companies to warrant the effective achievement of both product quality and quantity. Such warranty, which is difficult to sustain due to the intrinsic nature of geological uncertainty, can only be achieved through an increased efficiency in the mineral supply chain. This work demonstrates the benefits of creating models of existing mineral supply chains to identify and understand the points of value creation and places for possible improvement interventions. It also gives a modeling guide, through an electronic chart, enabling users to model any kind of supply chain. The knowledge of the process path from extraction to final consumer provides a unique opportunity for managers to improve the mineral supply chain. After the model has been created, it should and must be improved. A number of techniques and good practices already in use by other sectors but not yet applied to the mining industry are identified and structured. A methodology to strategical application of these techniques in provided. The mining industry all over the world is under pressure to look for methods to improve its efficiency. This work leads the way to an innovative managerial strategy in mining that has proved itself extremely competitive in other industries. The key issue addressed in this work is how to identify a robust and risk-controlled path for the mining industry to benefit from the lean thinking approach, introducing the concept of Lean Mining.

La demande mondiale en ressource minérale en général et celle du phosphate en particulier connait une forte croissance depuis plusieurs années. C’est dans ce contexte tendu que chaque industriel cherche à être pionnier et à réduire ses coûts afin d’assurer sa pérennité tout en étant soumis aux contraintes légales dans une perspective de développement responsable. Face à des enjeux comparables, plusieurs industries manufacturières se sont orientées avec succès depuis plusieurs décennies vers l’approche japonaise du Lean Management. C’est pour cette raison que nous avons réfléchi à proposer à travers ce projet de recherche une méthodologie pour le Lean Mining Responsable visant à améliorer l’efficacité et l’efficience de l’industrie minière. L’ensemble des méthodes, briques logicielles et concepts proposés dans cette thèse ont été construit à partir d’un retour d’expérience réalisé sur le système minier d’extraction du phosphate de l’axe centre de l’OCP SA. Nos travaux, réalisés sous la forme d’une recherche action, se caractérisent par des apports à 3 niveaux :Apports méthodologiques ; nous proposons la Méthodologie ASCI-LM pour évaluer l’impact sur l’organisation industrielle liés à la mise en place d’outils et de méthodes en contexte minier. Cette approche constitue un guide méthodologique permettant une recherche action dans le contexte de l’industrie minière. Ce guide méthodologique explique comment formaliser les modèles de connaissance (cartographie des flux) et comment imbriquer les modèles informatiques permettant d’évaluer informatiquement des scenarios organisationnels liés à des problèmes de coordination des activités en contexte minier.Briques logicielles pour l’aide à la décision ; l’interdépendance spatio-temporelle qui caractérise la chaîne minière, rend difficile la prédiction de l’impact de la décision prise. Ce point est un facteur-clé qui explique la démotivation de l’industrie minière à l’égard de la mise en œuvre du Lean Mining. Un système d’aide à la prise de décision pour l’industrie minière aura comme objectif de pouvoir reproduire la réalité et par la suite de tester l’impact de différentes décisions en prenant compte de : l’état du gisement, le programme de maintenance, la disponibilité des machines, les demandes à satisfaire… Les décisions prises dans le processus extractif auront comme impact sur : l’évolution des stocks de minerai, l’occupation des machines mobilisées, la satisfaction de la demande… Nous proposons deux briques logicielles dont la première porte sur la planification minière pour assurer un pilotage intégré de la mine et aider à la prise de décision dans un délai court. La deuxième brique logicielle que nous avons imaginée évalue / optimise les méthodes d’organisations industrielles de la mine lors de la constitution des « mélanges » de minerai ; le mélange de minerai constitue l’output commercialisable du système minier et qui est envoyé aux clients internes ou externes de la supply chain minière. Nouvelles méthodes d’organisation industrielle ; Nous avons proposé une méthode de constitution des mélanges de minerai qui change complètement celle utilisée actuellement. Cette dernière est basée sur une logique de nomenclature figée alors que nous proposons des nomenclatures dynamiques que nous avons appelés « blending dynamique ». Ces nomenclatures dynamiques visent à définir les mélanges optimaux qui varient au fil du temps en fonction des minerais extrait du chantier et de leur composition chimique. Malgré les réticences qui pouvaient y avoir pour adopter cette approche (ce qui est logique dans une organisation « historique »), les mineurs ont montré un grand intérêt vis-à-vis de l’approche qui a été validée sur le terrain et qui est même généralisable sur d’autres contextes. / Global demand for mineral resources in general, and phosphate in particular, has been growing strongly for several years. In this increased competitive environment, every industry seeks to be pioneering and to reduce its costs to ensure its sustainability while complying with new responsible development regulations. Faced with this kind of challenges, a number of manufacturing industries have turned to the Japanese Lean Management approach. With this in mind, we designed our research project to develop a Lean Sustainable Mining methodology aimed at improving the mining industry’s efficiency and effectiveness at the OCP-SA center axis phosphate mine. We first conducted a detailed review of the Lean Mining (LM) literature to assess how well such an approach had already been implemented, which points are directly relevant to the mine and which are not. We also reviewed the implementation methodologies and assessed how effectively they were used. This analysis highlighted multiple shortcomings including in relation to the methodological approaches, the software bricks for decision support systems, the industrial organization methods and adequate factoring in of all energy-related aspects.We first recommend applying the ASCI (Analyze, Specification, Conception, Implementation) methodology to LM in order first to identify all the steps upstream of development of the relevant knowledge model and then the associated action model. This phase was developed based on a thorough analysis of mine soil characteristics in order to build a robust knowledge base. This methodology was then applied to the Ben Guerir mine. We believe that this methodological approach will be found useful by other industries in their effort to switch to LM.Our next step was to construct a model based on discrete event simulation for short-term decision support of mine extraction planning. This model closely matches current extractive process operations (drilling, blasting, etc.) and takes into account all the constraints whether they be in relation to the field (geology, blocks, state of the initial system, distances, ...) or to the equipment (capacity differences, technical downtime, ...). Other considerations that we factored in include the decisions taken upstream of the chain (priority source layers, maintenance program, orders, among others). The model yields the following output: deposits blocks to be extracted in order to meet the demand defined over the planning horizon, the equipment Gantt to define the route to be taken by each piece of equipment and the cumulative feed curves for extracted source layers. The purpose is to extract material required by the downstream blending process, while avoiding any non-value added activities, and to improve overall chain performance.The phosphate industry needs to define the blends used to produce the ore qualities to be shipped to domestic and international customers. We have proposed a new method for optimal definition of these blends designed to replace fixed bills of materials by dynamic ones that change over time. Our "dynamic blending" model serves to define, based on available source layer stocks i) the feedings to be conveyed from the deposit to the stock and ii) the optimal quantities to be extracted from each layer while meeting the customer’s quality specifications charter. The purpose of this approach is to produce the right quality, preserve the phosphate-rich layers for the future, streamline stocks and ensure a connection between the pushed upstream flow (deposit) and the pulled downstream flow (definition of blends). / إن الطلب العالمي على الموارد المعدنية بشكل عام، والفوسفاط على وجه الخصوص، يزداد بسرعة منذ عدة سنوات. وفي هذا السياق الذي يعنى بمنافسة قوية بين الأطر الفعالة، يسعى كل مصنع الى أن يكون الرائد في مجاله، وأن يقلل من تكاليف الإنتاج من أجل ضمان متانته في إطار خضوعه لقيود قانونية تحت منظور التنمية المسؤولة. في إطار مواجهة قضايا مماثلة، انتقلت العديد من الصناعات التحويلية، بنجاح لعدة عقود، إلى تطبيق النهج الياباني Lean Management. ولهذا السبب، فكرنا من خلال مشروع البحث هذا في اقتراح منهجية من أجل Lean Mining مسؤول، هدفه تحسين كفاءة وفعالية صناعة المعادن. جميع الطرق والمنهجيات ومفاهيم البرمجيات المقترحة في هذه الأطروحة يتم بناؤها على أساس تجارب منجزة على نظام الصناعة المعدنية لاستخراج الفوسفاط للمحور المركزي لـ OCP-SA. يتميز عملنا، الذي تم تنفيذه على شكل بحث-عملي، بمساهمات على 3 مستويات:مساهمات منهجية: نقترح منهجية ASCI-LM لتقييم تأثير تنفيذ أساليب على المنظمة الصناعية المتعلقة بالصناعة المعدنية. هذا النهج هو عبارة عن دليل منهجي للبحث-العملي في هذا المجال، الذي يشرح كيفية إضفاء الطابع الرسمي على نماذج المعرفة (رسم خرائط التدفقات) وكيفية تضمين النماذج المعلوماتية التي تجعل من الممكن تقييم سيناريوهات تنظيمية تتعلق بمشاكل التنسيق بين الأنشطة في سياق الصناعة المعدنية.أسس البرمجيات لدعم اتخاذ القرار: إن الترابط الزمكاني الذي يميز سلسلة التعدين اللوجستيكية يجعل من الصعب التنبؤ بأثر القرار المتخذ. هذا الترابط يعتبر العامل الرئيسي الذي يفسر إبطاء صناعة التعدين فيما يتعلق بتطبيق ونهج سياسة Lean Mining. يهدف نظام دعم القرار الخاص بصناعة التعدين إلى إعادة إنتاج الواقع ومن ثم اختبار أثر القرارات المتخذة، مع الأخذ بعين الاعتبار: هيئة المنجم، برنامج الصيانة، توفر الآلات، المطالب الواجب تلبيتها ... القرارات التي اتخذت في سلسلة عملية الاستخراج سيكون لها تأثير على: تطور مخزونات المادة الخام، مدى استعمال الآلات المخصصة لذلك، و تلبية المطالب ... نقترح اسسين اثنين من البرمجيات: يتناول الأول تخطيط التعدين لضمان الإدارة المتكاملة للمنجم والمساعدة في اتخاذ القرار في وقت قصير. أما الثاني فيهتم بتقييم / تحسين أساليب التنظيم في المنجم أثناء تكوين "خليط" انطلاقا من المواد الخام؛ ويعتبر هذا الأخير الناتج النهائي القابل للتسويق في إطار النظام اللوجستيكي للتعدين، ويتم إرساله إلى الزبناء الداخليين أو الخارجيين لسلسلة التوريد.أساليب جديدة للتنظيم الصناعي: لقد اقترحنا طريقة لتكوين خليط من المواد الخام والتي تختلف تماما عن الطريقة المستخدمة حاليًا. وتستند هذه الأخيرة على منطق التركيبة الثابتة في حين أننا نقترح تركيبات ديناميكية أطلقنا عليها إسم "المزج الديناميكي". تهدف هذه التسميات الديناميكية إلى تحديد الخلطات المثالية التي تتغير بتغير الوقت، اعتمادًا على المواد الخام المستخرجة وتركيبتها الكيميائية. وبالرغم من الإحجام عن تبني هذا النهج (وهو أمر طبيعي في إطار تنظيم ذو أسس "تاريخية عريقة")، فقد أظهر عمال المناجم اهتماما كبيرا بالنهج المقترح والذي تم التحقق من مصداقيته في هذا المجال والذي من الممكن تعميمه في مجال صناعي آخر.