Game-changing digital shutdown software solution

The Customer

Our innovative open pit gold mining client processes approximately 15mtpa of sustainable mill throughput and is an ASX Top 100 listed company. The site is located in a remote part of the South-western Pacific and employs roughly 4,500 people.

The Situation

The client suffered from shutdown overruns and was looking for smarter ways to bolster its asset utilisation and strengthen its business position. The organisation believed using an end-to-end digital platform and standardising its processes could be the key to improving its shutdown performance. The organisation turned to the IMMS team and their specialist cloud-based shutdown solution, SMSi, to make the new strategy possible.

Like many resources organisations, our client used a number of different digital platforms and relied too heavily on spreadsheets to manage its schedules. Processes varied from team to team, and there was little consistency, continuity, or clarity across each event, making end-to-end shutdown management difficult. Limited data visibility throughout the project also affected the site’s ability to accurately track and measure results, impacting overall productivity and increasing risks to the business.

Running a complex business on an isolated island also presented our client with some unique challenges. Any preferred solution had to work efficiently and effectively with limited, and sometimes intermittent, connectivity.

This sizeable and remote project was made even more challenging due to COVID-19, which made it harder to access resources and manage the ever-changing quarantine, safety, travel, and logistical requirements.

The Solution

  • Prioritised planning and ‘front end loading’ to set the organisation’s shutdown events up for success.
  • Rolled out the SMSi solution and trained more than 200 users to effectively manage shutdown event readiness, execution, and post-shutdown activities. Maintenance teams swifty adopted the user- friendly technology.
  • Removed spreadsheets as the tool-of-choice and provided a reliable, cloud-based, and end-to-end shutdown management system.
  • Empowered shutdown execution supervisors with mobile devices, so they had task and schedule information at their fingertips to make ‘real time’ progress updates in the field.
  • Collected shutdown progress data from the field and made these insights available via easy-to-use and powerful dashboards to speed up decision making.
  • Enhanced accountability and transparency across the entire shutdown program.
  • Enabled users to analyse process compliance and use dashboard data to improve performance over time.

The Results

  • Improved plant utilisation by 3% in FY22.
  • Saved more than US$10 million in a fiscal year due to fewer shutdown overruns.
  • Delivered a standardised solution offering complete visibility and transparency.
  • Improved user experiences across team members and contractors alike. The easy-to-use and intuitive solution increased productivity and provided a sustainable technology platform for the future.