Client Situation
An underground operating mine was failing to meet production and development plans while exceeding both operating and maintenance budgets. The question was why?
Complications
The two-week fly-in rotating crews had no site management overlap resulting in almost non-existent communication and coordination, and very poor compliance with the mine plan.
Silo thinking evident with poorly defined business processes, disjointed workflows, and inter-departmental coordination resulted in management often working at cross-purposes across shifts and rotations.
Supervisors lacked the management tools to actively supervisor crews resulting in operating problems not being addressed on a timely basis.
The mine dispatch system had been configured and implemented poorly with minimal training resulting in it not meeting operational needs of the mine.
All mobile equipment – trucks, drills, and scoops had been out-sourced to the OEM supplier under a maintenance and repair contract. They failed miserably and dramatically impacted production.
Solution
We designed and installed management operating systems for mine planning, operations, and maintenance areas. Trained supervisors to actively supervise while enhancing inter-departmental coordination, and improved short-term scheduling of work creating a culture of continuous improvement.
Results
Our client realized an $11.5 Million annual savings realized with no capital investment required.
A significant win for them!
