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“The value derived from the PIP intervention is on record. However, more important to me is that the fundamentals of sustainabilty have been addressed - and I would like to thank the PIP team for a most satisfying and rewarding experience. Their value add is evident both in our business and in our personal growth..”

Gerald Boting,
General Manager,
Skorpion Zinc,
Anglo Base metals

Facilitated discussions between regional and
national bodies of Minerals Association
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Reduction in the number of contractors, enabling the higher frequency and intensity of interfacing between client and contractors, and improving the sustainable economics of contractors.

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Value optimisation facilitation for greenfields
bauxite mine and alumina refinery
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High-level confirmation of potential for 15-20% value savings achievable through 15 major idea areas

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Iron Ore - Major Mine Expansion
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Identified potential for a 15% increase in volume resulting in an incremental NPV impact of $700M

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Port and Rail CAPEX improvement
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Reduction of capex to near original PFS figure – savings of over 20%

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Service Delivery Optimisation: Outsource versus Inhouse
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Reduction in the number of contractors, enabling the higher frequency and intensity of interfacing between client and contractors, and improving the sustainable economics of contractors.

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Precious Metal Refinery
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20% improvement in EBIT

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40% reduction in overtime across the site

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Capital optimisation for an emerging Iron Ore producer
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Identified $202m in Capex reduction ideas through multiple idea generation sessions

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Launching continuous improvement for a
East European coal producer
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Increase mine volumes by 6-10% with the existing equipment and crews by reducing downtime and increasing throughput rate

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Open Cast Coal Mine
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98% of YTD budget achieved, making budget for the first time in 5 years

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Capital Reduction Diagnostic for an Engineering Consortium
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Conforming bid redesigned to come in at 52% of original bid

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Capital Optimisation for a global coal producer
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Identified 120 ideas with an initial value of $1.2 billion through multiple Idea Generation Sessions

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Australian Media Company
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20% of FTE spend eliminated by (i) eliminating outcomes, (ii) reducing targeted service levels, and (iii) simplifying tasks

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Additional 20% of FTE spend transferred back to the BUs for rationalisation

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Division of a Global Miner
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Separation of the 2 businesses without increased headcount

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29 % decrease in G&A headcount relative to pre-merger organisation

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European Nickel Refinery
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$40 million saving in capital cost

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4% increase in output above record production rates, with minimal capital spend

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European Copper Refinery
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80% improvement in "on-spec" loop production (essential to the elimination of cathode downfall

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75% reduction in cathode downfall

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Multi-site Miner
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Over $380m of cash was delivered to the bottom line in 6 months (annualised rate of $530m)

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First cash savings were flowing within 1 week of project inception

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European Head Office Metal Purchasing
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Over 100% increase in tonnes of cobalt produced from custom feed sources

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Approximately $50 million in additional, annualised revenue generated

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Rapid Sourcing - Coal
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Locked in savings of ($8M) within 10 weeks.

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Open Cut Coal Mine
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ROM coal production raised by 45% (12.5Mtpa)

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Raised the capacity of the mine’s major bottleneck, explosive loading, by 73%

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Capital Optimisation – African Underground Mine
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Increased the potential project NPV by roughly 500%

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Increased the maximum potential annual output from the mine by 50%

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Capital Optimisation –
Brownfield expansion of underground Nickel and Copper mine
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Improved the project’s NPV from below zero to over $250 million

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Capital optimisation – Iron ore mine/rail/port system
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20% CAPEX reduction on the primary project under review

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Hard wiring the operation for a successful capital commissioning
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Build the management infrastructure for a multi-billion dollar, greenfield, mining and processing site

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Iron Ore Developing Nation
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The PIP ROCX process identifies the drivers of value

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Infrastructure Bottleneck
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impartial diagnosis and shared pathway forward

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Iron ore port and rail system
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Increasing overall weekly tonnage rate by 35%

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Increasing ship loading rates

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Contractor Reduction - Major Iron Ore House
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Reduced contractor spend by $30m p.a. within 4 months of being on site

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Multi-plant metals processor
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Improvements have been recorded and sustained in almost all performance metrics

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Business Process Outsourcing (BPO)
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Performance turnaround at a leading provider of global outsourcing services

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Capital Project Delivery Assurance
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Identified areas of weakness and high risk in the approach to project execution

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Iron Ore Train Load Out
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63% reduction in railway Wagon Total Turnaround Time (WTT)

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60% reduction in Wagon Handling Time (WHT)

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Procurement - steel (2)

In eight months they had locked in $20m of savings with an additional $56m in implementation.

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Procurement - steel

Total value of ownership driver trees

Reverse engineered suppliers’ costs

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Underground Coal Mine (3)

28% increase in ROM tonnes production rate

10% increase in prime product yield

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Underground Nickel Mine

40% reduction in loader (a bottleneck) breakdowns

11% increase in LHD availability

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Contract Miner Performance Improvement

A number of Contract Mining Companies have engaged PIP to make improvements in their already lean businesses

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Underground Copper Mine
22% improvement in tonnes to the surface
25% improvement in tonnes to passes
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Copper Processing and Smelting
EBIT improvements of $80m for the financial year, and $140m+ on an annualized basis
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Open Pit Coal Mine
Delivered 4 out of 5 months of increased EBIT
Increased extracted coal to exposed inventory ratio
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Strategic Sourcing - Financial Services
Reductions in hardware & software maintenance cost
Significant reduction in contractor hours utilised
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Metals Mine
20% improvement in truck load factor
38% improvement in production drill metres
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Zinc Mine & Refinery
US$4m savings delivered
US$9.5m
in implementation
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Procurement
Reductions in spend per category ranging from 39% to 6%
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Metal Smelter (2)
$7.7 million reduction in costs
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Underground Coal Mine (2)
28% decrease
in costs per
ton of power station coal
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Diamond Mine
weekly underground development
up 50%
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Open Cut Iron Ore
Increasing truck load factor
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Underground Coal Mine (1)
Highest average daily production rate in past 27 months.
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AsiaPacific Call Centre
Level 1 Resolution Rate Improvement
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Nickel Mine and Smelter
The best 4, 5 and 6 month production periods in plant history
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Integrated Steel Mill
Throughput increased by 52%
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Arctic Diamond Mine
20% increase in tonnes mined
7% reduction in total mine costs
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Metal Smelter (1)
Cost curve rank improved from 55% to 15%
Annual improvement of 30.5m/yr
Free cash flow up by 123%
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Australasian Metal Manufacturer
$80m annualised improvement
Reduction of total number of injuries by 15%
Production increase: Zinc & Silver up 28%, Lead up 25%
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Integrated Chain: Commodity Producers/Rail/Port
18% increase in throughput in 4 months
Logistics system de-bottlenecked
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Australian Mobile Phone Company
4.5% reduction in total spend, 24% saving on costs tackled by PIP
Reduced inbound call centre costs by 55%
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Integrated Metals Manufacturer
Cumulative EBIT benefit of $26m
Annualised improvement of $34m/year
Cost/tonne down 28%
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European Paper Mill
26% increase in production
   - folio up 52%
   - A4 up 38%
   - rolls up 13%
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Recycled Fibre Plant
EBITDA increased from $0m to $12m
Production up by 31%
Variable cost down 22%
Total downtime reduced from 11 to 4 hrs/wk
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UK Paper Mill
UK coated market share increases of 110%, UK sheet sales up by 153% (£155/t margin benefits for UK sales over export alternative)
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US Packaging Manufacturer
Reduced procurement spend by 15%
Significant consolidation in suppliers
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Multinational Mining & Mineral Processing Company
8.5% reduction in procured spend in 8 months*
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Mineral Processor
Increased tonnes by 19% in 6 months
16% increase in line rate
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Rapid, sustainable results

 

Our Clients' Results Index

FACILITATED DISCUSSIONS BETWEEN REGIONAL AND NATIONAL BODIES OF MINERALS ASSOCIATION

VALUE OPTIMISATION FACILITATION FOR GREENFIELDS BAUXITE MINE AND ALUMINA REFINERY

IRON ORE - MAJOR MINE EXPANSION

PORT AND RAIL CAPEX IMPROVEMENT

SERVICE DELIVERY OPTIMISATION: OUTSOURCE VERSUS INHOUSE

PRECIOUS METAL REFINERY

CAPITAL OPTIMISATION FOR AN EMERGING IRON ORE PRODUCER

LAUNCHING CONTINUOUS IMPROVEMENT FOR A EAST EUROPEAN COAL PRODUCER

OPEN CAST COAL MINE

CAPITAL REDUCTION DIAGNOSTIC FOR AN ENGINEERING CONSORTIUM

CAPITAL OPTIMISATION FOR A GLOBAL COAL PRODUCER

AUSTRALIAN MEDIA COMPANY

DIVISION OF A GLOBAL MINER

EUROPEAN NICKEL REFINERY

EUROPEAN COPPER REFINERY

MULTI-SITE MINER

EUROPEAN HEAD OFFICE METAL PURCHASING

RAPID SOURCING - COAL

OPEN CUT COAL MINE

CAPITAL OPTIMISATION - AFRICAN UNDERGROUND MINE

CAPITAL OPTIMISATION - BROWNFIELD EXPANSION OF UNDERGROUND NICKEL AND COPPER MINE

CAPITAL OPTIMISATION - IRON ORE MINE/RAIL/PORT SYSTEM

HARD WIRING THE OPERATION FOR A SUCCESSFUL CAPITAL COMMISSIONING

CAPITAL OPTIMISATION - IRON ORE

INFRASTRUCTURE BOTTLENECK

IRON ORE PORT AND RAIL SYSTEM

CONTRACTOR REDUCTION - IRON ORE

MULTI-PLANT METALS PROCESSOR

BUSINESS PROCESS OUTSOURCING (BPO)

CAPITAL PROJECT DELIVERY ASSURANCE

IRON ORE TRAIN LOAD OUT

PROCUREMENT - STEEL (2)

PROCUREMENT - STEEL

UNDERGROUND COAL MINE (3)

UNDERGROUND NICKEL MINE

CONTRACT MINER PERFORMANCE IMPROVEMENT

UNDERGROUND COPPER MINE

COPPER PROCESSING AND SMELTING

OPEN PIT COAL MINE

STRATEGIC SOURCING - FINANCIAL SERVICES
METAL MINE
ZINC MINE & REFINERY
COAL PROCUREMENT
METAL SMELTER (2)
UNDERGROUND COAL MINE (2)
DIAMOND MINE

OPEN CUT IRON ORE

UNDERGROUND COAL MINE (1)

ASIA PACIFIC CALL CENTRE
NICKEL MINE AND SMELTER
INTEGRATED STEEL MILL
ARCTIC DIAMOND MINE
METAL SMELTER
AUSTRALIAN METAL MANUFACTURER
INTEGRATED CHAIN: COMMODITY PRODUCERS/RAIL/PORT - DEBOTTLENECKED
AUSTRALIAN MOBILE PHONE COMPANY
INTEGRATED METALS MANUFACTURER
EUROPEAN PAPER MILL
RECYCLED FIBRE PLANT
UK PAPER MILL
US PACKAGING MANUFACTURER
MULTINATIONAL MINING AND MINERAL PROCESSING SITE
MINERAL PROCESSOR
 

Access detailed analysis

Access detailed analysis of process, timing and outcomes by clicking the see detailed analysis links beside specific projects

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