Operational Excellence at work in a large corporation

Case Studies

Operational Excellence at work in a large corporation

The largest producer of iron ore pellets in North America needed to determine how it could increase throughput and reduce cost per ton of its largest mining operation. This operation, consisting of two separate pit mines and plants, had been struggling for the past several years to meet financial and production expectations. The lack of visibility into its day-to-day processes had contributed to the past and current operational performance problems. These problems culminated in a $65 million shortfall against the previous year’s production commitments.

Three months into a new Improvement Operating System, the plant began to turn the corner on several of the seven KPI areas. Production recovered from a $7.5 million deficit and trended to be on track for the year, energy spending improved by $500,000 per month, and safety accidents improved by 20%.

Activities in this case study include:

  • Value Stream Analysis
  • Performance Analytix®
  • Improvement Operating System

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