Mining and Metals: Solving Top Industry Challenges

Published on 18 Jul 2024

The mining and metals sector forms a fundamental pillar of the global economy. It drives economic activity and supports many industries. In 2023, this sector generated over $600 billion in revenue. Despite this, it faces many challenges. These issues slow down operations and hurt growth.

Over the past 15 years, operating margins in this industry have dropped. They went from 25% to just 10%, showing the need for better strategies and innovative solutions. This direct dives into these challenges and presents arrangements, including real-life case thinks and commonsense insights.

Challenge #1: Decentralized planning and scheduling processes

In the mining and metal industry, work order flow is critical. Decentralized planning can lead to inefficiencies. A user-friendly maintenance solution can help. These arrangements streamline workflows without complex navigation.

User-friendly interfaces allow employees to manage work orders quickly. Centralized dashboards enable real-time tracking. This minimizes the manual information section and diminishes downtime.

Case Study: How a Coal Producer Centralized Their Scheduling

An Australian coal producer faced fragmented planning. They needed a simple, efficient system. They adopted Prometheus Planning & Scheduling and Reporting & Analytics solutions. This change made reporting more efficient, leading to a significant improvement in productivity. The modern framework permitted for consistent arranging and planning. Technicians no longer had to navigate multiple screens. Cost management improved with easy-to-generate reports. This drove to way better asset assignment and expanded profitability.

Challenge #2: Lack of centralized documentation and tracking

Mining operations often span across different regions. This makes centralized planning difficult. Extracting and printing documents with SAP work orders can be a logistical nightmare. Simplifying these processes is crucial.

Case Study: How Cameco Improved Visibility and Efficiency of Work Orders

Cameco Corporation faced complex SAP functions. They are required to streamline forms and progress communication. Prometheus Planning & Scheduling was their solution. It simplified SAP functions and automated documentation collation.

With this solution, Cameco staff saved hours each day. Tasks that took 20 minutes were now done in 30 seconds. This efficiency boost allowed planners to focus on critical tasks. Improved coordination led to smoother maintenance activities.

Challenge #3 involves moving away from outdated systems towards real-time planning

Legacy systems in the mining industry are often outdated. They lack the agility needed for modern operations. This can lead to inefficiencies and poor resource utilization. Advanced technologies can help transition to real-time planning.

Case Study: Liberty OneSteel’s Successful Migration

Liberty OneSteel used an old planning system for two decades. It became inefficient and unreliable. For enhanced planning and scheduling, they adopted Prometheus Planning & Scheduling as part of their SAP migration. This move streamlined their processes and improved productivity.

The new system reduced the need for complex customization. Users reported saving 20 minutes per work order. This increased productivity and employee satisfaction. Liberty OneSteel became more agile and responsive.

Challenge #4: Manual and time-consuming data entry into ERPS

Manual data entry in SAP is a big challenge for mining teams. Errors and inefficiencies are common. Accurate data capture is vital for equipment reliability and maintenance optimization.

Case Study: Joy Global Boosts Efficiency and Data Accuracy

Joy Global provided maintenance services but lacked a mobile solution. They relied on manual data entry, which led to errors. Prometheus Mobility Solutions changed this. Technicians could enter data on-site, even without the internet.

This improved data accuracy and productivity. Joy Global maintained up-to-date records of maintenance activities. By streamlining the process, the company achieved better decision-making and improved operational efficiency.

Overcoming Obstacles & Advancing Growth Through External Solutions

The case studies highlight common issues in the mining and metals industry. They show how advanced solutions can address these challenges. By adopting these strategies, organizations can achieve operational excellence and sustained growth.

To address your unique challenges, schedule a demo with our experts today. Download our whitepapers for deeper insights and comprehensive solutions.