In the mineral processing industry, where every tonne counts and operational efficiency determines profitability, Operational Equipment Effectiveness (OEE) emerges as a key metric. OEE is more than just a number—it’s a lens through which operations and processing managers can assess the health of their plant. But achieving high OEE in a mineral processing plant isn’t straightforward. It’s a journey through challenges like fluctuating ore grades, equipment wear in harsh environments, and the ever-present pressure to meet production targets.
Let’s explore this journey—breaking down OEE into its core elements, leveraging digital tools, and looking at real-world success stories to see how plants can turn challenges into opportunities for sustainable improvement.
The Fundamentals: What Makes Up OEE?
At its heart, OEE is built on three pillars: Availability, Performance, and Quality. Each plays a distinct role in painting the bigger picture.
- Availability measures how often equipment is ready to run during planned production time. Frequent breakdowns or extended changeovers eat into this metric, reducing uptime and leaving teams scrambling to stay on schedule.
- Performance evaluates how efficiently equipment runs compared to its design capacity. Bottlenecks, slow cycle times, and inefficiencies all contribute to performance losses, turning potential output into missed opportunities.
- Quality focuses on how much of what’s produced meets the required standard. Off-spec product due to inconsistencies or equipment issues not only wastes resources but can also undermine customer confidence.
OEE provides a roadmap for uncovering these inefficiencies and taking targeted action to resolve them.
The Digital Edge: Using Technology to Improve OEE
Digital transformation has reshaped how plants approach OEE improvement. Tools like digital twins and IoT-connected sensors allow operational managers to simulate scenarios, identify bottlenecks, and respond to real-time data insights. These technologies empower teams to predict problems before they happen and fine-tune operations for maximum efficiency.
Paul Mitchell (author and EY Global Mining & Metals Leader) surmised that productivity in mining, minerals and metals could be enhanced by improved management of varibaility. In the article, Paul provided some key considerations for managing variability:
Image source – EY Graphic on productivity
At Mipac, we’ve seen the transformative power of digital tools in action. For instance, our Automation Roadmap for Ok Tedi provided a clear path for optimising equipment performance, reducing downtime, and aligning operations with long-term business goals. Digital solutions, when combined with a structured approach, allow plants to tackle inefficiencies head-on.
Step 1 : Improving Availability
A common challenge in improving OEE is extended changeover times. Inefficient changeover procedures can lead to significant production losses. By streamlining changeover processes, reducing setup times, and ensuring clear communication between shifts, manufacturers can minimize downtime and maximize overall equipment effectiveness.Take the Asset Management System implemented at Ok Tedi, where Mipac’s expertise enabled real-time tracking of equipment health. This system not only minimised unplanned downtime but also extended asset life, leading to long-term savings.
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Mipac Insight:
An often neglected opportunity is the role operators play in ensuring equipment stays healthy via routine operational checks and tasks. Importantly, failure doesn’t tend to happen straight after a check is missed. It’s usually after the second or third time. Having a digital tool that schedules routine operator tasks and escalates when critical controls are missed once or multiple times will help prevent downtimes and increase availability.
Step 2: Enhancing Performance
Performance losses are often tied to inefficiencies in how equipment operates. Addressing bottlenecks, maintaining consistent feed quality, and adopting advanced process control (APC) can significantly boost performance.
For example, during the Loadout Facility Optimisation Project, Mipac optimised material handling systems to reduce cycle times and streamline operations. This led to more predictable output and fewer delays.
Actionable Tip: Start small. Breaking performance improvements into manageable projects makes them easier to implement and sustain. Incremental changes often lead to substantial long-term gains.
Step 3: Raising the Quality Bar
Quality isn’t just about meeting specifications; it’s about minimising waste and maximising yield. Root cause analysis and real-time data tracking are invaluable tools for maintaining high-quality output.
Mipac Insight:
By integrating real-time quality monitoring, escalation and recommendations, we help operators respond to missed tasks instantly, preventing off-spec production and reducing losses.
Overcoming Practical Challenges
No improvement initiative comes without hurdles. Resistance to change, particularly when introducing new tools or processes, can slow progress. Engaging teams early, providing comprehensive training, and maintaining clear communication about the benefits are essential to overcoming these barriers.
At Mipac, we’ve learned that the key to sustainable change is involving employees at every stage. Whether developing an Automation Roadmap or deploying advanced tools, ensuring buy-in from end users is critical to long-term success.
A Roadmap for Sustainable OEE
Embarking on the journey to improve OEE requires a clear and structured approach:
- Define the case for change: Understand why improvement is necessary and align it with business goals.
- Identify the bottleneck: Use data and insights to pinpoint where inefficiencies are occurring.
- Engage stakeholders: Cross-functional collaboration is key, involving everyone from finance to operations.
- Implement and iterate: Start with manageable changes, measure their impact, and build on successes.
- Sustain the gains: Define measures of success early and use digital tools to monitor progress and ensure lasting improvements.
Conclusion: From Challenges to Gains
Improving OEE in mineral processing isn’t an overnight fix. It’s a journey that requires vision, the right tools, and a commitment to change. But the rewards—higher productivity, lower costs, and greater profitability—make it worth the effort.
The stories from Mipac’s work with clients like Ok Tedi, Kamoto Copper Company, Whitehaven Coal and others highlight what’s possible when expertise and technology come together. By taking the first step—assessing your plant’s current OEE performance and exploring tailored solutions—you can unlock the potential of your operations and set a course for sustained success.
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