Case Studies
iXcede helps client deliver US $146M boost in production
eXcellerate’s premier data analytics product iXcede uncovered an 8% increase in overall production across a fleet of rope shovels and hydraulic excavators, providing targeted, unbiased and actionable feedback to operators, translating to a sizable estimated annual revenue boost of US $146M.
A recent assessment of a client operator performance system revealed critical data insights for a top 12 global Copper producer, leading to significant operational improvement in their Electric Rope Shovels, 500T Hydraulic Excavators and Ultra Class Haul Trucks.
CHALLENGES
The current performance system did not assess on a ‘like for-like’ (LFL) basis preventing behavioural performance uplift.
The client required a trusted and engaging system, allowing individual operators to understand their strengths and identify areas for improvement and in addition, a means to accurately identify high performing operators ensuring optimised machine time.
The client has also identified their average truck load weights were significantly less than their 306t target and required improvement in this area and an overall productivity uplift.
FINDINGS & SOLUTIONS
eXcellerate’s iXcede software was able to highlight critical insights into the operation;
- Operators regarded as high performing, when assessed on a LFL basis, were in fact performing below average.
- Some operators who had been classed as low performing, when assessed on a LFL basis, were actually high performers.
- The ability to readily and accurately identify high performing operators leading to strategic allocation of resources.
IMPACT
- Overall, operators were provided with unbiased, accurate and targeted performance feedback improvement their digging capability.
- The client was able to recognise an increase in truck weights of 7% over an 8-month period.
- Average truck weights consistently surpassed the initial target of 306t, with a decrease in bucket cycle time of 8% and an increase in overall production of 8% also identified.
OVERVIEW
A recent mining client had identified significant inefficiencies and increasing unit costs with their blasting and explosive handling practices on site, specifically relating to the management of reactive ground.
Reactive ground, if not managed, can pose a significant risk to personnel due to the potential for a spontaneous exothermic reaction after certain sulphides present in the rock come into contact with nitrates in explosives. As per industry norms, bulk explosives suppliers require site testing for the presence of reactive ground, however the standard testing method (currently utilised by our client) was found to be unrepresentative of the actual risk conditions specific to their site.
Operating multiple coal mines, the potential value of unlocking a bespoke solution for this issue was not just a significant bottom line improvement, but also one of safety and risk management.
The eXcellerate process brought together coal mine health and safety, explosives blasting and research and risk management experts in a structured way that ensured a sound understanding of the technical issues and potential solutions, while also enabling consultation with all key site and risk owner stakeholders.
Our Approach:
- Sharing our deep, accumulated industry experience
- Breaking down silos to foster a culture of collaboration
- Instilling confidence in the team to challenge existing assumptions Enhancing the technical skills of the planning and operations teams
- Encouraging innovative thinking by questioning assumptions previously accepted as facts
- Bringing together industry talent and expertise to achieve informed and lasting outcomes
KEY ACTIONS TAKEN
The scope included compiling the latest engineering and scientific data on the detonation of Ammonium Nitrate in reactive ground.
Additionally, site data and research were utilised to understand associated risk factors with risk assessments conducted to create a reactive ground management procedure, supporting stakeholders to select the most suitable explosives.
A discovery workshop was facilitated, bringing together industry experts, former regulators and site personnel to review the relevant data, research and regulatory frameworks leading to the development of informed and specific site-based procedures.
KEY FINDINGS
A suite of reactive ground testing techniques and subsequent data analysis were found to be suitable, accurate and could be made readily available for site personnel on the ground (with the support of site geological/geochemistry personnel) providing a representative result of the level of reactive ground present.
This information has allowed the selection of blasting products and explosives that not only meet industry standards for managing reactive ground, but also provide an optimised blast outcomes at a significantly reduced unit cost.
Reduction in dragline rehandle from 135% to 70% through strategic design and sequencing
OVERVIEW
eXcellerate was engaged to enhance dragline productivity for a major mining client. Leveraging decades of experience in dragline operations, eXcellerate identified and executed strategies delivering a significant step-change in performance and a US $30M improvement in just one strip.
KEY ACTIONS TAKEN
To achieve this remarkable improvement, several strategic actions were implemented:
- Optimised Blast Timing:
By carefully adjusting the blast timing, we were able to double the cast prime.
- Geotechnical Constraints:
We tested and removed unnecessary geotechnical constraints, giving the dragline greater flexibility in positioning, which improved overall efficiency.
- Dig Method:
Changing the dragline dig method reduced rehandle and increased the consistency of coal flow, streamlining operations.
- Scheduling:
We restructured the drill and blast schedule to optimise dragline sequencing, ensuring the most effective use of spoil room.
THE EXCELLERATE WAY
At eXcellerate, we docus on building long-term capability, not just delivering technical solutions/. By investing time in one-on-one coaching and leading group discussions, we empower our client teams to challenge the status quo and foster collaboration.
Our approach:
- Sharing our deep, accumulated industry experience
- Breaking down silos to foster a culture of collaboration
- Instilling confidence in the team to challenge existing assumptions Enhancing the technical skills of the planning and operations teams
- Encouraging innovative thinking by questioning assumptions previously accepted as facts
- Bringing together industry talent and expertise to achieve informed and lasting outcomes
THE OUTCOME
A substantial bottom line saving, and a valuable increase in the capability and confidence of both planning and operations teams. This step-change not on improved dragline productivity but also reinforced a culture of continuous improvement and innovation within the organisation.