Client Profile:Canadian Potash Producer
Services Provided
- Integrated Mine/Mill Planning
- Maintenance & Reliability
- Training & Development
- Management Systems
- Risk Assessment & Mitigation
- Mill Debottlenecking
- Annual Shutdown Planning
- Capital Project Management
- Warehousing
- Rail Logistics
Challenge
- Global potash producer sought to align all departments’ planning and execution of high-capacity proving run with multi-year consultant engagement
- After undergoing expansion, including new mill and shaft, the site required a proving run to set the new capacity, worth $215MM+ annually
- Run required high availabilities and utilization of all major assets including original Mill, New Mill and the Borer Fleet, at previously un-proven levels
Approach
- Integrated Mine/Mill Planning
- A comprehensive sitewide engagement addressed new requirements across all departments and functional groups: Procurement, IT Support, HR, Mine and Mill Maintenance, Engineering & Planning, Reliability, and Mine and Mill Production
- Developed and implemented integrated mine plan, with auxiliary functions such as construction, equipment overhauls, and manpower inputs
- Established staffing and training requirements, and tracked hiring, training, and recruiting
- Conducted FMEAs in the Mine and Mill, developed workarounds, and refined PMs
- Developed Annual Shutdown schedule and coached planning and scheduling resources
- Coordinated several test runs in Mine and Mill
Result
- Produced 14% above corporate target and doubled nameplate capacity
- Availability of Original Mill increased from 91% to 97%
- Availability of Borer Fleet increased from 87% to 90%
- Cutting hours increased 120%
- Balanced crew staffing & eliminated “no manpower” equipment delays
- Completed commissioning process for new Hoist and Mill. Achieved 100% of target production within 6 months
”We achieved far more than we ever hoped to achieve and couldn’t have done it without your help. Your team provided exactly the support we needed”
- President
