Mining is an industry of high stakes and tight margins, where the pressure to meet production targets often clashes with the realities of operational setbacks. But when a mine is on the brink and struggling to recover lost ground, innovative approaches are essential to regain momentum.
But OIM Consulting is helping mining companies navigate these challenges by delivering tailored programmes that drive immediate improvements while laying the groundwork for sustained success. One such success story is the turnaround of a major coal producer, proving that the right intervention can restore operations and exceed expectations.
When the coal mine in question faced mounting challenges in 2023, including inefficiencies and bottlenecks in its plant processing and stockyard sections, the outlook for meeting annual targets looked grim. Says Arjen de Bruin, Group CEO at OIM Consulting: “With production lagging and sales tonnage far below expectations, the management team knew drastic action was required and thus they engaged our Supervisory Development Programme (SDP).”
The programme’s strategy was clear and focused on three critical pillars. It began with leadership alignment, ensuring management prioritised performance drivers that could deliver the greatest impact. High-impact initiatives targeted bottlenecks in the value chain, addressing operational inefficiencies head-on. Meanwhile, frontline leaders underwent intensive training to equip them with the skills necessary to drive consistent, high-performing shifts. Together, these efforts create a foundation for recovery and sustainable improvement, explains De Bruin.
The results were nothing short of remarkable. In just four months, the mine clawed back 1.2 million tonnes in sales, meeting its annual target for the first time in 13 years. Plant productivity soared, with a 25% increase in runtime and a 14% boost in tonnes processed. Consistency in direct operating hours improved by over 300%, while sales tons delivered rose by 20% – all attributable to improved supervisory performance.
From crisis to consistency
Beyond the numbers, the turnaround at the mine reflects a deeper transformation in operational culture. Structured management systems, real-time problem-solving practices, and visual management became integral to daily operations. Supervisors – who underwent intensive on-the-floor coaching – played a pivotal role in driving these changes, ensuring the improvements were not only immediate but sustainable. “Our approach always starts with people, as without the buy-in of our frontline leaders our efforts are fruitless,” says De Bruin.
Building a sustainable future
OIM Consulting’s Supervisory Development Programme ensures that mines can maintain these gains over the long term. “By embedding a culture of continuous growth and aligning operational practices with organisational goals, we seek to ensure that our clients are well-positioned for consistent, high-performance results in the future,” concludes De Bruin.