Case Study: Improving Production Efficiency at a Remining Site in the DRC

Background:

A remining operation in the Democratic Republic of Congo (DRC) included four remining sites and eight sections. However, the operation faced frequent downtime, leading to a loss of flexibility and adversely affecting the blending and supply processes. A service provider was tasked with supplying spare parts for the remining equipment, pumps, and valves. An analysis by Envision Advisory Services (EAS) identified several key challenges contributing to the inefficiencies.

Challenges Identified:

I.?Supply Chain Constraints: The geographical location and lack of OEM supply resulted in excessive and fluctuating turnaround times for spare parts.

II. Limited IT Infrastructure: The absence of an integrated warehouse management system hindered efficient inventory management.

III. Lack of Stock Control Expertise: The service provider lacked sufficient knowledge in stock control, exacerbating inventory management issues.

IV.?Inadequate Demand Planning: Usage and demand planning were hampered by the use of reconditioned parts, substitutes, and borrowed items, leading to skewed data.

V.?Insufficient Preventive Maintenance: Failure to adhere to preventive maintenance practices resulted in unforeseen downtime and excessive wear on parts.

Solutions Implemented:

I.??Demand Planning Model: EAS developed a demand planning model using historical usage data and estimates, with continuous refinement as data capturing disciplines improved.

II.?Kanban-based Stock System: A Kanban-based stock system was developed and implemented to streamline inventory management.

III. Training and Practical Demonstration: Training sessions were conducted for all involved parties, with practical demonstrations during the development and implementation stages to ensure understanding.

IV.?Reintroduction of Preventive Maintenance Disciplines:

·????Visual management techniques were introduced to overcome language barriers and enhance understanding.

·????Team Involvement: Operational staff were actively involved at all levels to foster a culture of preventive maintenance.

·???? Management coaching and support were provided to establish and reinforce desired behaviors.

?Outcomes:

• Enhanced Efficiency: The processing plant increased efficiency to sustain operations of the mining site.
• Improved Spare Part Availability: Activation of supply chains led to improved availability of spare parts, reducing downtime.
• Reduced Emergency Maintenance Costs: The reintroduction of preventive maintenance practices resulted in decreased emergency maintenance costs.

Conclusion:

By addressing the identified challenges and implementing targeted solutions, the remining operation in the DRC significantly improved availability, efficiency, and effectiveness in production within the existing resource constraints.