Base Metals Mining Operation
Following the turmoil of the difficult market conditions in 2009, many parts of the sector are now undergoing a revival as demand increases and the operating environment looks far more favorable.
Within recent months companies have seen their revenue streams reach record levels on the back of the current commodity prices boom fueled in part by the increased demand from emerging markets and especially India and China. Unfortunately, metals prices do not rise in isolation and the increase in price for crucial commodities such as fuel and rubber has also hit mining companies hard. While the immediate outlook may appear to be positive, in the event prices decline and costs remain high, there are a number of areas companies should consider investing in now in order to assure their future. These areas include:
- Energy usage and conservation
- The optimization of maintenance practices and management
- Improving logistics and procurement strategies
- Training staff at all levels to be able to operate proficiently
- Installing systems and program that will manage change quickly and effectively
The development of a tailor-made change-management system involves establishing where bottlenecks may occur, both physical in terms of plant and equipment as well as human resources and then progressively removing constraints or identifying ways in which they can be managed successfully. The development of relationships between people at all levels within an operation is essential as a means of generating engagement in decision-making, and in implementing management improvements. Such strategies must also be sustainable, with the repeated achievement of incremental short-term improvements leading to major long-term change, thereby providing a platform for continued profitability.
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Our Results
Our metals clients have included almost every metal from aluminum to zinc. Regardless of the specific commodity or mining process, a disciplined review of the operation has permitted the identification and implementation o f significant financial benefits.
Although the scope for improvement varies between mines, most clients see very significant throughput increases, improved equipment availability and reduced direct costs per ton. Mining clients typically show returns of over 3:1 on their investment.
| Throughput and Equipment Utilization: |
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Increased payload per truck by 12% at a South American ferro nickel mine while exceeding the budgeted percent availability for the aging fleet |
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Increased throughput by 30% ata lead, zinc, copper and silver operation in South Africa |
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Increased mine throughput by 12% with the same infrastructure at a copper zinc operation in Turkey. Recovery increased by 2%. |
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Service levels increased by 42% in the locomotive workshop of an African copper mine |
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Increased concentrator throughput by 5% and raised copper recovery by 1% at an Indonesian copper mine |
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| Resource Productivity: |
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Increased maintenance productivity by up to 45% and raised the percentage of repairs completed within 24 hours from 76% to 92% |
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Increased the productivity of a large contractor team by 20 to 30% at an open cast nickel-laterite mine |
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| Materials and Energy: |
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Reduced tire and fuel consumption by 25 and 17% respectively at an African zinc operation |
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Increased tire run hours by 30% at a mine in Indonesia |
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A moisture management system in the ore feed from the mine to the process plant resulted in a 4% high sulfur fuel oil consumption reduction |
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Testimonials
The financial benefits are measured and tracked monthly and the trend is showing that the improvements expected are being realised. Proudfoot were able to gather momentum quickly, responded to our needs and were able to show results early on in the process. I highly recommend them.
Head of Mining, Black Mountain
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Case Studies
Mining business-wide improvement program results in $8 million in savings Read more >>
Indonesian copper mine realizes $42.5 million in savings by increasing throughput and cutting costs Read more >>