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 Results - Mineral processor

Context / scope of project : This site was performing well and making attractive profits. They had made numerous improvements in the past years but the rate of improvement was slowing down as the easier opportunities were systematically captured. Managers at the site had seen PIPs work at a number of other sites and felt that our approaches could help take them to the next level. Our brief was to help them identify where the improvements lay, implement the changes, transfer skills and create a high performing organization which could continue to improve long after we were gone.

Client achieved:

Increased tonnes by 19% in 6 months

16% increase in line rate
Increase in uptime from 93% to >95%

12% reduction in process chemical usage

14% reduction in usage of primary fuel

16% improvement in secondary fuel efficiency

5% reduction in treated oil usage






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What we did:

Clarified roles and accountabilities throughout the organisation

Introduced rigorous target setting and performance reviews down to shift supervisor level
Debottlenecked plant
Migrated organisation from reactive maintenance to planned maintenance
Worked with suppliers to increase quality and/or volume of critical inputs


 
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