Our Results: Underground Coal Mine (3)

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Results - Underground Coal Mine (3)

Context / scope of project : This underground coal mine was consistently profitable. New owners were keen to drive operations improvement to increase profitability. After a diagnostic with PIP identified significant potential improvements, we engaged on a joint endeavour to capture those savings.

PIP and client achieved:
	28% increase in ROM tonnes production rate
	10% increase in prime product yield
	6% increase in total product yield
	88% reduction in production machine breakdown hours
	An improvement idea pipeline > 50% more valuable than the project target
	A sustainable continuous improvement culture – results continued to improve post-PIP’s departure

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What we did:

	Increased metres per blast by intensive front-line coaching
	Established Results Action Review (RAR) meetings from GM down to front-line which drove: Reversal of a low compliance and authoritarian "command-and-control" culture by establishing a culture of accountability and auditing Increased working hours by focussing on shift start and end times Increased underground load and haul productivity – minimised distances to feeder/breaker through more frequent belt extensions and retreats
	In engineering we reduced breakdowns – overheating being the biggest initial issue – by implementing a vigorous “FLAC” (fuels, lubricants, air and coolants) program, RCAs (systematic root cause analysis processes), and consistent use of Pareto analysis on breakdown causes.
	In the washing plant we increased yield by reducing variability in plant operations by driving a short interval control mentality through daily “dashboard” meetings and rigorous use of RCAs for failures.