iXcede Unlocks Record Dragline Production in 6 months

Explore how iXcede enabled record dragline productivity, higher utilisation and measurable value creation across a four machine open cut mining fleet.

As part of a broader productivity and cost reduction initiative, iXcede enabled a major uplift in dragline performance at a large Australian open cut coal operation. The operation relied on four draglines operated by more than 60 operators, with draglines forming a critical lever in total waste movement and mining cost control.

From the outset, site leadership sought a combination of outcomes. These included increased production, improved asset utilisation, stronger workforce capability and a sustainable reduction in the cost of mining coal. Rather than pursuing short term gains, the operation partnered with eXcellerate to use iXcede as a platform for long term, repeatable performance improvement.

The Challenge: Low Prime Productivity and Distorted Performance Insight

Before iXcede was deployed, dragline performance sat well below what would normally be expected for the machines in operation. Prime productivity was materially low, annual operating hours averaged well below 7,000 hours per machine, and fleet rehandle exceeded 120 percent. These factors constrained production, increased cost pressure and limited the dragline fleet’s contribution to overall site performance.

Data quality further compounded the challenge. For instance, one dragline suffered from a bucket payload calibration error that artificially suppressed reported dig rate and rehandle figures. The inaccurate reporting masked improvement opportunities and reduced confidence in decision making.

To address these issues, eXcellerate was commissioned to transform dragline performance using iXcede, with a clear mandate to lift productivity, improve consistency and materially reduce mining costs.

The Approach: iXcede’s Like for Like, Operator Focused Insight

iXcede enabled a fundamentally different approach to performance improvement. Rather than relying on headline metrics such as dig rate alone, iXcede provided true like for like analysis across operators, machines and operating conditions. This removed distortion caused by geology, pit design and task allocation and allowed the site to focus on genuine performance drivers.

Crucially, iXcede combined high resolution performance data with validated insight from eXcellerate’s experienced mining professionals. This ensured that recommendations were practical, credible and immediately applicable on site.

Success was defined through measurable improvements in dragline productivity, utilisation, rehandle and consistency, supported by improved data confidence and a clear link to cost reduction and performance.

Using iXcede to Embed Consistency and Capability

iXcede enabled eXcellerate and site teams to move quickly from insight to action. Key actions included:

Identifying and correcting data quality issues, including calibration errors, to restore trust in reported performance.
Establishing accurate, like for like performance benchmarks across the dragline fleet using iXcede.
Delivering targeted operator coaching based on how each task was executed in comparable conditions, not just production outcomes.
Supporting crew deployment and shift planning using validated performance insight.
Tracking consistency over time through iXcede to lock in gains and prevent regression

The program initially focused on a priority dragline to maximise early impact. Once initial improvements were established, iXcede enabled the approach to scale across the broader fleet.

The Outcome: Record Dragline Performance and +$40M Value Uplift

For the main dragline, iXcede enabled a sustained step change in performance, delivering record production outcomes, a 10 percent year‑on‑year increase in production and significant economic value within a six‑month period.

iXcede enabled this primary focus dragline to increase waste movement by more than 1 million bank cubic metres year on year, equating to an estimated $40 million increase in value for this machine alone. This uplift was driven by improved operator performance, higher utilisation, reduced rehandle and more accurate, trusted performance insight.

For the main dragline, iXcede also enabled:

A 32‑month record annualised dig rate.
Rehandle reduced to six percent below budget.
A four‑year prime production record.

Across the entire dragline fleet, iXcede enabled a six‑year record in dragline production, lifting the overall contribution of the dragline system.

As performance improved, the dragline system consistently delivered more than 50 percent of total waste movement, reducing reliance on higher‑cost truck and excavator methods and delivering a sustainable reduction in the site’s mining cost base.

Building Long Term Capability with iXcede

Beyond the production records, iXcede enabled a lasting capability uplift. Operators became more skilled and engaged through clear, actionable feedback, while leaders gained confidence in decision making supported by trusted, like for like performance insight.

By enabling accurate measurement, consistent execution and operator development, iXcede established a platform for sustained dragline improvement and ongoing productivity gains across the operation.