Scope:
Our client is a market-leading Iron Ore producer. With operations across 4 continents and employing nearly 8000 staff and contractors, it faces an outstanding growth challenge that will see it more than double annual sales over the next 5 years.

Operating in a highly constrained labour market coupled with a lack of productivity and quality improvement in this highly capital-intensive industry has led to a significant challenge in meeting demand.

Application:
LMR engaged the top executives in a workshop to gain an awareness of Lean and the potential it can bring to driving capacity. With a strong alignment at the top, the following three weeks were used to develop Master Schedules across the operation to deliver capacity results based on identified bottleneck processes.
In parallel to the Master Scheduling, an aggressive deployment of Information Centres both vertical and horizontal across the organisation was developed to enhance communication, problem solving policy deployment and waste elimination. Throughout the value chain, from mine to port, LMR coaches supported the introduction of stability tools to release potential capacity an over-arching production flow programme to manage ore throughput.

Results:
3000 employees are engaged daily in Lean. It is a way of life in the mine. ROI on LMR resource 190:1.

Future Plans:

• Increasing output
• Improved product quality
• Reducing material throughput time
• Reduced man hours per tonne
• Reducing Inventory and associated costs