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Operational excellence in mining

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. 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
  • Human Resource
     

 

Software Tools

 

GEN-OPS1: Standard Work Instruction

GENEO gas several Lean software tools available to improve operational excellence. Standard work instructions pose an ongoing challenge for many businesses. So, we developed GEN-OPS1 . It is an intuitive and effective cloud-based solution designed to simplify standards management. Your standards must stay up-to-date to be relevant, but they won't do it without regular review and editing. GEN-OPS1 makes it easier and faster to produce and manage great standards, including:

  • standardized work instruction
  • standard operating procedures
  • code of practice
  • etc.,
     

TEMPO: Critical Path Planning and Short Interval Control

Mining companies tend to look to ERP / CMMS for process control; consequently, optimization 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. TEMPO is a valuable addition to maintenance leaders seeking to:

  • Minimizing maintenance turnaround times
  • Reducing backlogs
  • Raising asset availability
  • Driving up continuous improvement

 

my-CI: Continuous Improvement

Continuous improvement is an important part of operational excellence for any business. Therefore, GENEO developed the my-CI Mobile App. This platform leverages mobile technology to access your Lean Operating System rapidly. GEN-iGO provides users with a convenient and intuitive way to:

  • Raise, track and measure concerns
  • Record and share continuous improvement insights
  • Access top-down visibility continuous improvement in all teams
  • Sustain your Lean Operating System
     

GENEO's lean software tools are an excellent addition to any mining company's effort to achieve and maintain operational excellence, so contact us for a free consultation and a demo.  

 

Client Group: Mining


Scope Introduces Lean Operating System to reduce operating cost


Diagnostic 4 week diagnostic from pit to port


Actions

  • It introduces buffer management across the value chain
  • Introduces production control to comply with the principle of pull and synchronize mines with demand
  • Introduces TPM on haulage fleet to move from 'utilization' to 'effectiveness'
  • Introduces Information Centers to drive shift, daily, and 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
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. This is because dependence on over-production introduces risks to the plan; while it may reach targets, it can also yield costly defects. Defects can present in several ways, including safety, higher operating costs (delays, availability, reliability, attendance), and unplanned resource consumption to name a few. Any of which potentially pose a threat to life of mine and investor confidence.
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GENEO continues to grow its business based on the great results we achieve with our clients. No engagement is ever the same, each one presenting a unique set of challenges for our team, challenges that we heartily accept and overcome jointly with our clients.
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We are training leaders to make a difference by leading Lean with the appropriate behaviours to make a significant difference to their Continuous Improvement culture. It’s all about people and we are all about people.
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Reduce maintenance turnaround time by 50%!
  • TEMPO is a system that has been developed to radically reduce the time taken to perform complex maintenance activities on fixed assets or fleet. It is a simple yet intelligent way of organizing your maintenance activities to complete the maintenance turnaround in half the time.
  • By organizing work sequences for trades/technicians and building critical paths and dependencies, TEMPO quickly highlights lost time opportunities in the overall planned turnaround.
  • Applying standard work instructions with step-by-step guides for process confirmation, TEMPO visualizes real-time progress for short interval control, providing instant decision making to maintain compliance to plan.
  • By using TEMPO to plan and execute complex maintenance turnarounds our clients have achieved 50%+ reduction in downtime, giving a 10%+ improvement in fleet availability.
Reduce maintenance backlog by 60%!
  • Unlock valuable maintenance time and use it to reduce chronic backlogs or stubborn deferred defects.
  • Give technicians more time for proactive interventions.
Improve asset reliability by 18%!
  • Enjoy the knock-on benefit of backlog clearance and proactive activities, improving the reliability of your assets.
Increase continuous improvement engagement by 180%!
  • TEMPO’s easy-to-use Concerns and Ideas capture feature engages technicians in driving improvements that help improve turnarounds, reliability, and availability
  • Identify the classic wastes (transport, inventory, motion, waiting, over processing, over production, defect) in relation to your maintenance activities.
  • Expose supply chain, kitting, resourcing, workplace organization, sequencing, tooling, and planning opportunities for review through TEMPO’s powerful reporting feature.
  • Analyze the hour-by-hour compliance to plan with the associated losses incurred throughout the turnaround event.
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