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 Results - Nickel mine and smelter

Context / scope of project : The site, while profitable due to high commodities prices, was plagued by inconsistent performance and high costs. An all encompassing focus on day to day operational issues precluded any impact on these core issues. Our mandate was to assist in prioritizing the major issues, identify solutions, and maintain the focus required to see the solutions through, all the while transferring the skills to maintain the momentum we created together.

Client achieved:
The best 4, 5 and 6 month production periods in plant history
A permanent process to identify, prioritize, implement and sustain improvement opportunities
$25M (6.3%) in annualized cost savings, with a pipeline of $20M (5%) more
Best ever autoclave availabilities (the bottleneck)





 

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What we did:

Value driver trees: “Where’s the money?”

Debottlenecking of process plant
Revised maintenance strategies for pumps and autoclaves
Cascaded performance management system from Gm to supervisor (accountabilities, scorecards, reviews)
Aligned incentives site-wide
Contractor management
Cost reduction: consumables, raw materials, inventory, equipment hire
Variablity reduction (operating procedures, shift handovers, morning meetings, audits, variance reporting)
Backlog management, workorder management


 
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