Context / scope of project:Mature mine with end of underground life in 2.5
years. Buy-ins and alternative sources of coal were
key to overall economics due to insufficient feed from
underground to plant. New, competent yet incomplete
management team. Becoming increasingly difficult to
hire and retain talented staff. Key management objectives
were to sustain positive EBIT and morale, and retain
staff.
PIP
and client achieved:
Highest average daily
production rate in past 27 months
Highest consistent plant throughput
levels (2 year record of 7 months consistently over
1m tonnes pm through plant), while not compromising
quality
20% reduction in misplaced material
(ie less quality coal sent to dump)
Increased daily mini-pit production
by an average of 50% within one month of PIP project
start
Introduced to plant 60,000 tonnes/month
of duff (dumped material of adequate quality to
process)
Raised stacker-reclaimer utilization
to a consistent 95%+ from 25% on arrival, ensuring
more consistent feed and quality to the plant
Considered best managed mine in the
group from being rated worst managed in the prior
year
Operational profitability sustained
and staff turnover very low
Created Value Driver Tree of Integrated business
– paretos for micro level improvements and macro level
restructure
Implemented disciplined Results Action Review (RAR) process,
strongly driven by GM and operations manager.
Created clear feedback loop between mine captains and teams
Focused on performance variances and disciplined prioritisation
Unlocked major new source of revenues in mini-pits
Coached operators, miners and overseers on cutting sequence
and cutting cycle standards
Conducted root cause analyses (RCA) on
• belt downtimes
(underground and overland)
• plant downtime
• costs in staff transport,
telecoms, third party logistics
Increased module capacity by reconfiguring to match feed mix
Developed HR tracking process to aid communication, prioritisation
and acceleration of recruiting process
Introduced formal periodic reviews with key suppliers and
contractors