Case Studies
Middlemount South – Foxleigh Mine
- Transition Manager responsible for the mobilisation of mining and maintenance contract
- Onboarding of mining fleet – 220t truck fleet, ancillary equipment including dozer, loaders, graders, water trucks and support equipment
- Demobilisation of existing contractor and equipment fleet
- Fleet statutory compliance and audit management
- Critical spares and component support and logistics
- Contract start up
Austin Engineering
- Global logistics and supply chain review covering North America, South America, Asia Pacific
- Manufacturing review and opportunities to consolidate and improve efficiencies
Sojitz
- Tender management for the supply of contract mining services and equipment
- Tender management for the supply of mining trucks, components and bodies – scope, development, process management and negotiation
BMC Poitrel Mine
- Investigation into statutory compliance – contractors and mining equipment
- Review of planning and scheduling of mandatory compliance tests and inspections
- Audit of evidence and quality of checks and inspections
Ensham Mine
- Assets and Equipment compliance audit – statutory compliance and maintenance execution review of owner and contractor assets
- Parts logistics and component audit
- Development and implementation of process improvement strategy
- Maintenance planning
- Work execution
- Machine compliance
- Safety systems review
- Maintenance inspections and NDT audit
- Failure analysis of dragline and grader issues
BMA Blackwater Mine
- Management of mobile equipment maintenance repair and execution
(160 personnel and 24 supervisors on four panel rosters) - Employee support and safety – Improved safety management and zero incidents
- Reporting and Key performance indicator improvement plans implemented
- Contract finalisation and demobilisation strategy
Project management of ancillary workshop – coal fleet and support equipment - BMA Maintenance Audit
- Review of contractor supplied maintenance
Individual plant and equipment audits on infrastructure, mobile mining equipment, rope shovels and fixed plant - Investigate maintenance shutdown and execution quality and advise on improving performance
- Departmental and management structural review
- Review of contractor supplied maintenance
McKinsey Consulting
- Subject matter expert (SME) for mining business digital transformation project
- Identify opportunities for the business and define the benefits of digital transformation
- Define methodology for the management of condition monitoring inputs
- Develop warning escalation process for these inputs
- Review of client Planning and Maintenance strategy and efficiency
- Mine site assets and mobile equipment auditing – remote location support
- Detailed review of mining truck fleet maintenance issues and product problems
- Audit and review of product issues and the development of a mining truck fleet management strategy for updates and modifications
Glencore – Hail Creek
- Critical spares audit for fixed plant, mobile equipment and electric shovels/dragline
Review of warehouse, supply chain and parts stock holding across the site - Identification of stock holding on and off the books
- Risk analysis for various machine types to identify parts and components inventory holding requirements
- Develop standard planned jobs and BOMS based on time and material actual input
- Develop recommended stock holding for support components and parts
- Implement parts and component storage management procedures
Bisha Mine Eretria North Africa – Copper and Zinc Mine
- On-site audit of Processing Plant Maintenance is to identify reasons for issues with recovery, reliability and performance as well as developing an action plan for rectification and sustainable improvement
- Transition management of the operation to a predictable and managed maintenance regime
- Baseline identification and assessment of condition of key production critical Genset, Solar and Power Generation / transmission equipment
- Current life expectancy of assets – Processing plant, Genset Life Cycle hours and replacements forecast
- Critical and support spares for the facility
Liebherr
- Production testing of new 70t class bulldozer – Develop strategy to conduct mining equipment productivity testing. Conduct productivity and comparison testing with competitive machines
- Advise on the market release strategy for new mining products
- Life cycle costing development and analysis on mining excavators, bulldozers and trucks
- Develop critical support requirements for new machine models – parts and components
- Development of machine and application specific maintenance strategies
- Operational and application severity reviews for various mine sites
Territory Generation – Northern Territory (Aust) Power Station Audit
Detailed maintenance audit of four power stations ranging in size from 25MW to 50MW utilising Gas turbine, diesel/gas engines and solar systems:
- Development of overarching maintenance strategy
- Planning and scheduling review – Defect management and rectification, shut down planning
- Audit maintenance procedures and work execution quality
- Review of maintenance management solution and functionality
- Risk analysis and reporting
- Infrastructure maintenance strategy development
OTML Ok-Tedi Mining
Infrastructure, Plant and Mobile Fleet selection for mine life expansion project including:
- Review of existing operations
- Logistics, parts and component supply review
- Identify in country support requirements from OEM suppliers
- Operator productivity and efficiency review
- Integration of mixed fleet of mechanical and electric drive trucks
Komatsu Australia SAP Project
- Komatsu Australia ERP evaluation for their parts and service operation.
- Engaged to review and map all processes for the operations and assist in development of the solution scope and specification.
- Detailed development of CRM requirements and specification
- Completed “As is to be” process mapping for asset management, part and service operations, sales and marketing
- Sales and marketing functional requirements
Wiggins Island Export Coal Terminal (WICET)
Transition to operations and operational readiness for the new 25mt coal terminal. Operational Readiness Team Lead – Support Infrastructure:
- ERP business solution and information Management Project
- Steering committee member for business solution implementation
- Asset management, procurement and warehousing scope definition and implementation
- Responsible for transition to operations of support infrastructure
- Warehousing and workshop design, specifications and construction
- Procurement of spares inventory
- Implementation of inventory management processes and procedures
- Support services and contractors – engagement of more than 60 individual services – procurement process, contract negotiations and site mobilisation
- Subject matter expert for plant and equipment maintenance management
- Developed maintenance strategy – train in-load, conveyor, stockpile, ship loading systems, and mobile equipment
- Mobile and ancillary equipment procurement and mobilisation
- Stockpile production testing, machine specification, tender management and procurement
HSE Mining – National Maintenance Operations Manager
Senior Management role with management and fiscal responsibility for maintenance operations and OHES across various mine sites, and the group support functions including planning and centralised rebuild facilities.
- Implemented departmental restructure
- Auditing and reporting – asset maintenance management and site processes
- Maintenance planning centralisation and site work requirements
- Development of component and equipment rebuild facilities and strategy
Forecasting, scheduling and planning for all maintenance expenditure - Contract and site mobilisation strategy
- Developed and implemented equipment maintenance strategies
XEMC Xiangtan Electric Manufacturing Group Ltd. China
Development and delivery of technical training for maintenance, faultfinding, testing, adjustment and repair of the Rio Tinto Tom Price Mine and Western Turner fleet of the 240tonnes Electric Drive Trucks:
- In consultation with factory engineers, developed learning outcomes for technician training including, maintenance processes and management, systems operation testing and adjusting
- Delivery of theory and practical training on site for technicians and service personal
Product improvement and updates and monitoring system - Life cycle modeling and costing for various truck models
Glencore - MacArthur River Mining
Zinc processing plant and concentrator audit, mobile equipment audit and process improvement:
- Detailed audit of processing plant and maintenance processes including mill, floatation systems, crushing and conveyors
- Maintenance strategy review
- Development of short and long term planning strategies for fixed and mobile equipment
- Review of shut down planning, execution and management
- Assessment of labour skill and full-time employee requirements for maintenance
Boliden Aitik Copper Mine – Northern Sweden
- XP4100 and 7495 Electrical shovel maintenance review
- Continuous improvement and root cause failure analysis of 26x engine failures
- Reliability centred maintenance (RCM) maintenance strategy development
- Mobilisation strategy for electric drive haul fleet
- Change management program development
- Mentoring and development of maintenance team
Lawson/INFOR Software
Engaged to provide industry expertise in the development, marketing and sales of a new ERP solution, primarily targeting OEM equipment dealers and mining businesses:
- Implementation of complete business solution for major Caterpillar dealers covering Europe, Australia and China
- Mentoring of sales teams and sales technique training
- Keynote presentations to global sales and development teams with a focus on education regarding the industry and its requirements in building a successful business system
- Development of change management strategy and implementation
- Process mapping of operating departments, sales and product support
Anglo Gold Ashanti (Global)
- Major accident investigation (serious incidents and fatalities)
- Fatality investigations Central Africa – mobile mining and haulage equipment
- Conduct major injury investigations
- Development of safety and fatigue management strategy
McColls Transport
Major national transport and logistics business covering general freight and bulk foods handling:
- Business process review and audit
- Strategy development for the business focusing on efficiency improvement and cost reduction covering operations scheduling, safety/driver fatigue management, and vehicle management
- Review of GPS tracking and reporting solutions
Mercedes Benz Australia Commercial Vehicles
Business Development Program across the branch network nationally to achieve improved revenue and profitability:
- Primary focus on improving margin and reducing expenses within the Parts and Service operations
- Mentoring of Branch Managers, Operational and Sales Managers
- Development of Commercial Vehicle Strategic Business Plan involving key management and personnel
- Contractor performance and contract review
