Iron Ore Case Study
Why is operational excellence in mining a challenge?
Volume targets notoriously drive mining; consequently, this can present ongoing challenges to operational effectiveness. A Lean Operating System focuses on reducing waste incurred from over-production.
Client
Iron Ore
Scope
Introduces Lean Operating System to reduce operating cost
Diagnostic
4 week diagnostic from pit to port
In-depth analysis
A Lean Operating System focuses on reducing waste incurred from over-production. This is because dependence on over-production introduces risks to the plan; while it may reach targets, it can yield:
- Increase safety incidences and property damage,
- Deviation from spatial compliance,
- Compromise product quality,
- Higher contractor costs,
- Poor coordination of sequential and parallel processes,
- Maintenance backlogs,
- Lower reliability
- Reduced availability
- Diminished Life of Mine
- Lower investor confidence
Any of the above will impact performance. Fortunately, GENEO can help by focusing on process design to reduce waste and empower your teams to engage in Continuous Improvement. Leading organizations have realized the benefits of adopting a Lean Operating System resulting in greater quality, lower costs, higher compliance to plan, better engagement from the workforce to contribute improvement insights, and drive out waste. Indeed, we can show your leadership how to build, sustain and grow a Lean organization. We have experience at all scales, including:
- Enterprise
- Mine site
- Mining execution,
- Maintenance,
- Engineering,
- Supply, and
- Human Resource
Actions
- It introduces buffer management across the value chain
- Introduces production control to comply with principle of pull and synchronise mines with demand
- Introduces TPM on haulage fleet to move from 'utilisation' to 'effectiveness'
- Introduces Information Centers to drive shift, daily, weekly interactions
Results
- Fleet haulage reduced by 6%
- Fuel costs reduced
- Auxiliary equipment reduced across the value chain
- Load cycle time reduced by 19% on average across mines
- 89% engagement of employees in Continuous Improvement and problem solving
Three solutions, one mission
All our software shares the same philosophy: simple enough for anyone and everyone to use, and capable of delivering measurable impact on efficiency and revenue.
We have several Lean software tools available to improve operational excellence. Standard work instructions pose an ongoing challenge for many businesses. So, we developed GEN-OPS. It is an intuitive and effective cloud-based solution designed to simplify standards management.
Mining companies tend to look to ERP / CMMS for process control; consequently, optimisation is hard to address. So we developed TEMPO to deliver critical path maintenance planning and short interval control. You can have operational excellence delivered by every technician in your maintenance bay and sustain it.
my-CI is an intuitive, flexible, and powerful mobile platform to accelerate and broaden workforce contribution to continuous improvement. Create checklists, unify your standards, and solve problems faster – all in one app.
Why we’re chosen
We specialise in digital solutions for lean manufacturing operations – and we’re proud to say nobody else does what we do.
With a team comprised of in-house software experts and consultants, GENEO are the all-in-one solution for organisations that value delivery and stability from a team they can trust. This also enables us to tailor our software for every client, and we’re constantly updating our tools to keep our clients ahead of problems and laser-focused on continuous improvement.
We’re confident that if you use our software properly, you'll see multiple times return on investment in cost savings. That's why we offer our pilots at low cost, with money-back guarantees, and we’ll only sell to organisations where we believe we can save you money.
Better standards, better work
Low risk, real results – our pilot programme lets our experts put GENEO software to action in your business, with no long-term contract and a money-back guarantee.
We’re ready when you are.