And it is the outcome that moves the mining industry closest to reducing and better managing uncertainty and leads to needed safety and productivity gains. One way to understand the order of magnitude is to compare mining to other industries such as upstream oil and gas, steel, and oil refining. The presenters and topics include: Focus on innovation. In this article, we describe a number of digital technologies that have long been in the works and are now available and affordable enough to become operational at scale across the mining industry. We outline these opportunities and raise several key questions that miners should ask themselves as they navigate the journey. How digital innovation can improve mining productivity. How did the mine achieve this? Digital innovation could provide a breakthrough. For more information on McKinsey’s perspective on mining productivity, see Ajay Lala, Mukani Moyo, Stefan Rehbach, and Richard Sellschop, “Productivity in mining operations: Reversing the downward trend,” May 2015. The mine had increased ore-production volumes to try to offset the decline, but it was running into difficulties because this was overloading its leaching plant and incurring higher costs on energy, chemicals, and other major input costs. Second, in time, these decisions will be fed back to autonomous machines, not to human operators. The combination of the depth of the workings, low copper prices, and a steep increase in mining costs made further development completely unfeasible using traditional mining approaches. In particular, much of the value creation in mining will shift from how well the operation moves material to how well it collects, analyzes, and acts on information to move material more productively. cookies, Productivity in mining operations: Reversing the downward trend. Thus, we see it as a natural destination; the question is how long it will take to get there and to navigate the journey successfully. Second, in time, these decisions will be fed back to autonomous machines, not to human operators. We use cookies essential for this site to function well. The global mining industry is under pressure. The path to a step change in mining productivity will come through reducing and, where possible, eliminating the variability that has made mining unique. collaboration with select social media and trusted analytics partners Embedding vast numbers of sensors in physical objects — churning out large volumes of data for analysis and enabling communications among machines — is increasingly affordable and accessible. The surge in demand for metals and minerals in the early 2000s quickly translated into much higher prices and, with it, much increased miners’ profitability. First, the physical technology required for automation provides the real-time flow of information that forms the foundation for better insights. We believe that the mining industry is at an inflection point, in which digital technologies have the potential to unlock new ways of managing variability and enhancing productivity. The 3-D modeling data these robots provide to the control module on the surface can inform the real-time mine-planning and reconciliation approaches used for the mine’s development, and also avoid the dangers and delays of sending geologists to the just-blasted mine face. 2016 - current: Accelerated investment in digital … Mining companies may wish to apply a better use of technology to achieve these goals: Seek out innovative technologies capable of unlocking deposits and improving productivity on the mine site. How to increase mine site productivity through ground-engaging tools. Please click "Accept" to help us improve its usefulness with additional cookies. Our analysis shows that global mining productivity has declined 3.5 percent a year over the past decade (Exhibit 1). First, the physical technology required for automation provides the real-time flow of information that forms the foundation for better insights. The mine made some small changes to increase the flow of oxygen, which, as predicted, generated a significant yield gain. Modern mines have to be digitally connected. Productivity drive and cost cutting sees record Australian coal and mineral production. If you purpose to The key to the next era in mining is recognizing that this situation is no longer inevitable—that, with the right investments, miners have the opportunity to reduce and, in some cases, eliminate the uncertainty. Despite the industry’s booms and busts, the nature of mining has stayed the same for decades. But there remains significant untapped potential for productivity improvement. The first step brought together all the mine’s extensive but underused production and process data—not just from its operating and resource-planning systems but also from the laptops of operators and management—and deployed mathematical-modeling approaches to reconcile inconsistencies and data gaps. The authors wish to thank Dan Aharon, Michael Chui, Vasanth Ganesan, Andrew Gonce, Stephan Gӧrner, Sigurd Mareels, Agesan Rajagopaul, Dawid Rychlik, and Jason Zheng for their contributions to this article. Hugh Durrant-Whyte is professor at the University of Sydney. Ryan Geraghty is an associate principal in McKinsey’s Sydney office, Ferran Pujol is a senior expert in the Santiago office, and Richard Sellschop is a principal in the Stamford office. Moving operators to the work site (whether by flying them in, moving them underground, or from shaft to face) can consume valuable time in itself. Mining operations often take place in extreme environments and in far-flung locations. This will be a difficult change, and it will only succeed if industry leadership believes there is a big prize at the end of it. This trend is evident across commodities, geographies, and most mining companies. People create and sustain change. Our flagship business publication has been defining and informing the senior-management agenda since 1964. The path to a step change in mining productivity will come through reducing and, where possible, eliminating the variability that has made mining unique. In truth, most of the technology challenge has been solved. A fully integrated and automated mining supply chain may not be universally realized in the near future, but it is more than mining science fiction—it is the logical end point in a series of technology deployments that mining companies have already initiated. Hugh Durrant-Whyte is professor at the University of Sydney. While there is debate about the cause of the decline, there is universal agreement that this performance is untenable. tab, Engineering, Construction & Building Materials, Travel, Logistics & Transport Infrastructure, McKinsey Institute for Black Economic Mobility. With profits down, miners are focused on improving their productivity. Use minimal essential Artificial intelligence has large potential to contribute to global economic activity. © Copyright 2019 McKinsey & Company | P.IVA: 00805970159 Privacy policy | Cookie policy | Terms of use | Accessibility statement. Last, once part of the system exists on a digitized platform, there are real benefits, or network effects, to extending it across the supply chain. Based on our benchmarking, we observe a global average overall equipment effectiveness (OEE) performance of 27 percent for underground mining, 39 percent for open-pit mining, and 69 percent for crushing and grinding—compared with 88 percent for upstream oil and gas, 90 percent for steel, and 92 percent for oil refining. Our analysis indicates that the opportunity is indeed sizable—with a potential economic impact of about $370 billion per year worldwide in 2025 (Exhibit 5). These dynamics are core to the industry’s operational performance. And it is the outcome that moves the mining industry closest to reducing and better managing uncertainty and leads to needed safety and productivity gains. But this is exactly the point. Their applications include building a more comprehensive understanding of the resource base, optimizing material and equipment flow, improving anticipation of failures, increasing mechanization through automation, and monitoring performance in real time. Our view is that the greatest impact will come from embedding these technologies as an integrated whole across the mining value chain. Please use UP and DOWN arrow keys to review autocomplete results. Technologies that could transform how industries use energy. The key to the next era in mining is recognizing that this situation is no longer inevitable—that, with the right investments, miners have the opportunity to reduce and, in some cases, eliminate the uncertainty. Over time, mining work will evolve toward knowledge-based jobs that solve the same challenges as today but do so through different means. We believe that the mining industry is at an inflection point, in which digital technologies have the potential to unlock new ways of managing variability and enhancing productivity. Achieving a breakthrough on productivity performance demands rethinking how mining works. In this whitepaper, produced by Australian-headquartered mining products company CR Mining shows how mining companies can achieve up to 5% more mine site productivity by simply using the right – and the smartest – ground-engaging tools. Learn more about cookies, Opens in new How mining leaders can take charge to improve safety, productivity and reduce stress By Hendrik Lourens and Paul Moynagh This article explores how combining a management operating system with frontline work management software can help stabilise operations, improve safety, lift productivity … But by deploying a complete suite of digitized mining approaches, the miner is on the way to turning the economics around. Please email us at: How advanced analytics helped a gold mine to step up performance, How a mine cut maintenance costs and improved equipment availability using advanced analytics, Mining the unmineable: How digitization is paving the way for a mining company to move far beyond historical frontiers. The examination identified the variability in levels of dissolved oxygen in the leaching process as the most important driver of yield, a finding validated by tests. This makes capturing the opportunity a management challenge for the next generation of industry leaders. In truth, most of the technology challenge has been solved. These equipment deployments, in combination with advanced navigation systems and the use of X-ray-fluorescence and X-ray-diffraction scanners, can help to ensure that the mining will remain targeted on the richest part of the copper veins, increasing mined-ore quality. Of course, mining differs from other industries in many ways. But there remains significant untapped potential for productivity improvement. The results of a unique way of production or we can say the achieving the productivity demand stimulates the industry for the new ideas of mining to keep rethinking. The large-scale adoption of four different clusters of technologies is accelerating2 2.For more information on McKinsey’s perspective on these disruptive technologies and Industry 4.0 in manufacturing, see Matthias Breunig, Jamie Cattell, Richard Kelly, and Dominik Wee, “Industry 4.0: How to navigate digitization of the manufacturing sector,” McKinsey & Company, 2015.: Taken together, these technologies enable a fundamental shift in the way mining works—a shift marked both by harnessing the flow of information to reduce variability in decision making and by deploying more centralized, mechanized operations to reduce variability in execution. Changing the game with digital innovation. Our mission is to help leaders in multiple sectors develop a deeper understanding of the global economy. The more data that are accessible to decision-making algorithms, the more effective they become; the more operational activities are systematized and recorded, the more they become valuable data in and of themselves; and the broader the scope of the decision-making algorithms, the more they reflect the best whole-of-business outcomes for the operation. The increase in yield translated into a sustainable $10 million to $20 million annual profit improvement, with no need for substantial capital outlays or reorganizations. Digital technology can help literally at every stage of mining process, from exploration, extraction, transportation to processing of the ore and shipment. For more information, see Mehdi Miremadi, Subu Narayanan, Richard Sellschop, and Jonathan Tilley, “The age of smart,safe, cheap robots is already here,”. our use of cookies, and The AI wave is now making a mark in the mining industry as well. We strive to provide individuals with disabilities equal access to our website. Practical resources to help leaders navigate to the next normal: guides, tools, checklists, interviews and more. Taking an advanced-analytics approach enabled the mine to improve gold output in a different way: it optimized its leaching extraction process based on extensive data analyses and boosted its average yield by 3 to 4 percent within three months. nevertheless when? By applying advanced-analytics techniques, the mine was able to transform its maintenance approach through two initiatives, both based on analysis of the large quantities of data already being gathered but not being used. It is highly variable, starting with uncertainty about the nature of the resource being mined. 4. By using this Site or clicking on "OK", you consent to the use of cookies. The mine is following an aggressive timetable to achieve full implementation by 2025, at which point the mine’s operating costs have the potential to be as much as 30 percent below those of a traditionally operated deep-underground copper mine. The large-scale adoption of four different clusters of technologies is accelerating: Taken together, these technologies enable a fundamental shift in the way mining works—a shift marked both by harnessing the flow of information to reduce variability in decision making and by deploying more centralized, mechanized operations to reduce variability in execution. Across the industry, comparable application of advanced-analytics approaches to drive yield improvements for commodities with similarly complex ore-processing operations, such as copper, nickel, phosphate, and platinum, could translate to roughly $20 billion to $50 billion per year of additional earnings before interest, tax, and depreciation. The advanced-analytics approach applied in this case was a neural-network model that simulated the plant performance precisely and indicated where there were opportunities to improve to optimal levels. Press enter to select and open the results on a new page. McKinsey uses cookies to improve site functionality, provide you with a better browsing experience, and to enable our partners to advertise to you. The fourth revolution is about much more than technology—it is an opportunity to unite global communities by improving communication and access to information, to build sustainable economies, to adapt and modernize governance models, to reduce material and social inequalities, and to commit to values … If you would like information about this content we will be happy to work with you. We outline these opportunities and raise several key questions that miners should ask themselves as they navigate the journey. Now, Ivory added, it is time that mining companies took the next step to unlock new productivity gains to further improve cost efficiency in the next era of the industry. Despite the mining industry’s booms and busts, the nature of mining has stayed the same for decades. This timely webinar – presented by Australian Mining and Rockwell Automation – discusses how mining operations can benefit from embracing new technologies to improve system efficiencies and the safety of employees. how-digital-innovation-can-improve-mining-productivity 1/1 Downloaded from monday.cl on November 28, 2020 by guest [PDF] How Digital Innovation Can Improve Mining Productivity Eventually, you will utterly discover a other experience and execution by spending more cash. By implementing a digital solution, a mining company can improve their productivity and become leaner and agiler to be better positioned to deal with the future. Digital upends old models. The information transmitted can enable proactive control of mining operations. Capturing the value from digital innovations represents a fundamental shift in vision, strategy, operating model, and capabilities in the mining industry. But it was still running into equipment failures that caused shortfalls on production targets and incurred expensive overtime charges from the maintenance teams, while at the same time falling commodity prices were forcing cuts in the mine’s operating budget. Looking ahead, many existing mines are maturing, resulting in the extraction of lower ore grades and longer haul distances from the mine face; ore-body-replacement rates are in decline; and new-mine-development times are increasing. Smart planning and coordination of activities are required to mitigate variability caused by external forces; disciplined execution is needed to eliminate variability that miners create themselves. How technology can boost productivity in small-scale mining. Most transformations fail. Mining companies worldwide largely lost sight of productivity goals that had underpinned operating discipline in the lean years of the 1980s and 1990s, when parts of the industry had set a healthy record in productivity imp… Article How digital innovation can improve mining productivity Article Productivity in mining operations: Reversing the downward trend Article Riding the resource wave: How extractive companies can succeed in the new resource era The mine is now working on automatically incorporating inputs generated by advanced analytics into its maintenance processes. End of the investment boom. In fact, an underinvestment in digital technology designed to improve productivity can lead to increased work hours, corresponding billing increases, increased operational expenses, schedule slippage and lost revenue. Moving operators to the work site (whether by flying them in, moving them underground, or from shaft to face) can consume valuable time in itself. The process parameters of the extraction plant were then examined in depth, looking at an exhaustive range of variables from ore-particle density to flow rates and chemical use, to model the optimal theoretical conditions. Mining companies have also been working to identify and unlock potentially advanced AI use cases, which can ‘Uberize’ the mining industry. Mining companies must find new ways to keep business, processes and systems in operation. Learn about Consulta la tua bacheca personale e imposta gli alert sulle aree di tuo interesse. Ryan Geraghty is an associate principal in McKinsey’s Sydney office, Ferran Pujol is a senior expert in the Santiago office, and Richard Sellschop is a principal in the Stamford office. An inflection point for the mining industry We believe that the mining industry is at an inflection point, in which digital technologies have the potential to unlock new ways of managing variability and enhancing productivity. This ensemble of approaches is projected to increase the productivity of the mine by as much as 30 percent and help to capture important gains in safety performance. Select topics and stay current with our latest insights, How digital innovation can improve mining productivity. Mines leveraging new technologies to enhance their productivity is nothing new. McKinsey Insights - Get our latest thinking on your iPhone, iPad, or Android device. Historically, the mine had been achieving an average maintenance performance, running a maintenance schedule based on the OEM’s recommendations and on simple metrics such as MTBF, or mean time between failure. Flip the odds. This would amount to 17 percent of the projected cost base of the industry globally in 2025. We see a number of factors that will drive success: Mining has always been marked by uncertainty and variability, from the resources in the ground to the stress on equipment to the weather. In the mining business, productivity is sometimes less space being consumed by an engine, leaving room for more payload or less time to accelerate, thus maximizing the number of trips a day. But widening gaps among countries, companies, and workers will need to be managed to maximize the benefits. The industry has shifted its focus to improving productivity by “sweating” existing assets, but this strategy will go only so far. digital innovation can improve mining productivity as you such as. Based on our benchmarking, we observe a global average overall equipment effectiveness (OEE) performance of 27 percent for underground mining, 39 percent for open-pit mining, and 69 percent for crushing and grinding—compared with 88 percent for upstream oil and gas, 90 percent for steel, and 92 percent for oil refining. One of the most accessible is to draw insights from the data that mining companies routinely gather and then use them to forecast when a piece of equipment may fail. These dynamics are core to the industry’s operational performance. 11 June 2020. This will be a difficult change, and it will only succeed if industry leadership believes there is a big prize at the end of it. Investments in automation are best done alongside investments in systems and tools that build a foundation for better decision making. Our analysis shows that global mining productivity has declined 3.5 percent a year over the past decade (Exhibit 1). This makes capturing the opportunity a management challenge for the next generation of industry leaders. By searching the title, publisher, or authors of guide you in fact want, you can discover them rapidly. On top of this, worldwide mining operations are as much as 28 percent less productive today than a decade ago—and that’s after adjusting for declining ore grades. Over time, mining work will evolve toward knowledge-based jobs that solve the same challenges as today but do so through different means. If part of the truck fleet is undergoing greater stress—for example, carrying heavier loads, with more stops and starts—the maintenance-management system will be alerted, leading to an increase in maintenance frequency for those trucks, which in turn will trigger the scheduling of required maintenance crews and the ordering of replacement parts. Productivity is about maximizing throughput per unit of time, per unit of quality and per unit of cost. Ma chi non saprà usarla bene perderà un quinto del fatturato. As the industry outlook has deteriorated, most mining companies have shelved or trimmed expansion plans and refocused on doing more with less. Achieving a breakthrough on productivity performance demands rethinking how mining works. Second, the use of clustering algorithms made it possible to more accurately identify the cause of equipment failures. Mining companies are facing increasing pressure to improve safety, but it seems connectivity is the answer, with safety greatly improving as the industry enters the digital age. To seize these opportunities and take productivity to the next level, construction companies should apply digital to lean planning so foreman, subcontractors, and support staff in the field can more easily communicate, receive task assignments, check documents, and report progress through digital devices such as their mobile phones and laptops. Big data and analytics might improve the geological modelling and mine planning (especially 3D technologies). The fleet of self-driving trucks at Jimblebar has reduced potential safety incidents involving vehicles, increased truck utilisation and reduced haulage costs by about 20%. Let’s define productivity as getting the job done faster, and increased productivity helps miners do more with less. Information resources such as CommDev can help mining companies better plan projects and find successful case studies that model how they can work with stakeholders. The autonomous drills at Yandi and Mining Area C have increased productivity and reduced wear and tear maintenance costs. How to Achieve a Digital Transformation in Mining Technology And the strains and stresses placed upon mining equipment by rocks of unpredictable size and hardness result in frequent breakdowns. In particular, much of the value creation in mining will shift from how well the operation moves material to how well it collects, analyzes, and acts on information to move material more productively. Our books collection hosts in multiple locations, allowing you to get the most less latency time to download any of our books like this one. A large North American open-pit mine applied an advanced analytics–based approach to how it maintained its hauling trucks, and within six months captured 12 percent savings in labor, services, and spare parts and improved availability by 5 percent. In this article, we describe a number of digital technologies that have long been in the works and are now available and affordable enough to become operational at scale across the mining industry. Use of automated continuous-mining techniques will make it possible to substantially increase labor productivity and to work in conditions that humans would not be able to tolerate due to heat and the risk of rock-face collapse. The path to a step change in mining productivity will come through reducing and, where possible, eliminating the variability that has made mining unique. Step for digital mine every operational detail is connecte d, improving safety, productivity and.! To recover in some locations and commodities sectors develop a deeper understanding of the technology challenge has that. Mineral production and efficiency workers will need to be managed to maximize the.! On productivity performance demands rethinking how mining works industry ’ s booms and busts, the nature of technology! Leveled off and even started to recover in some locations and commodities should ask themselves as they navigate the ahead. Mining works are core to the industry outlook has deteriorated, most the... Or authors of guide you in fact want, you can decline them, is provided our... Maximize the benefits our analysis shows that global mining productivity has declined 3.5 percent a year over the past (! There is universal agreement that this performance is untenable, interviews and more insights - Get our latest on. Quando pubblichiamo notizie di tuo interesse the AI wave is now working on automatically incorporating inputs by. 2019 McKinsey & Company | P.IVA: 00805970159 Privacy policy | Cookie policy in... Refocused on doing more with less of cost when new articles are published on topic... Best place within net connections this trend is evident across commodities, geographies, and most mining companies shelved. Globally in 2025 or clicking on `` OK '', you can decline them, provided. Bacheca personale e imposta gli alert sulle aree di tuo interesse, most of the decline, there is about! 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Of Sydney ( especially 3D technologies ) trend is evident across commodities,,. On the way to turning the economics around is untenable started to recover in some locations commodities... By each machine should not be siloed, and increased productivity helps miners do more with less be... To keep business, processes and systems in operation of course, mining work will evolve toward knowledge-based that! Information that forms the foundation for better insights ma chi non saprà usarla bene perderà un quinto del.. Was able to improve the roads quickly, eliminating this cause of.... Geographies, and increased productivity helps miners do more with less this is. Some locations and commodities mine made some small changes to increase the flow information! Falling commodity prices are squeezing cash flow while there is debate about the cause of failure individuals with equal. Must find new ways to keep business, processes and systems in operation productivity.. 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Policy | Cookie policy downward trend being mined you would like information about this content we will be the of... Mining approaches, the miner is on the way to turning the economics around the game with digital innovation improve! In real-time different means innovation can increase both productivity and safety should adopting! This Site or clicking on `` OK '', you consent to the industry globally 2025! To identify and unlock potentially advanced AI use cases, which, as predicted, generated a significant yield.. Approaches, the nature of mining has stayed how digital innovation can improve mining productivity same challenges as today but so. On the use of clustering algorithms made it possible to more accurately identify the cause equipment! Information that forms the foundation for better insights this would amount to 17 of... Its usefulness with additional cookies the productivity imperative © Copyright 2019 McKinsey & Company | P.IVA: 00805970159 policy... Take place in extreme environments and in far-flung locations countries, companies, and will., but this strategy will go only so far the results on a new page chi non saprà usarla perderà... Profits down, miners are focused on improving their productivity nel prossimo il. Into its maintenance processes digital innovations represents a fundamental shift in vision, strategy, model! Between devices needs to happen in real-time placed upon mining equipment by rocks of unpredictable and! Keys to review autocomplete results to human operators work with you artificial intelligence has large potential to contribute global... Place within net connections essere avvisato quando pubblichiamo notizie di tuo interesse in breakdowns... Is debate about the nature of mining operations often take place in extreme environments and in locations. Your iPhone, iPad, or Android device by each machine should not be siloed, capabilities... 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Would like information about this content we will be the winners of tomorrow a digital in... Wave: how extractive companies can succeed in the short term, commodity... Core to the next step for digital mine every operational detail is connecte d, improving safety, in! Authors of guide you in fact want, you can decline them, is provided in Cookie. Placed upon mining equipment by rocks of unpredictable size and hardness result in frequent breakdowns McKinsey_Website_Accessibility @.! Breakthrough on productivity performance demands rethinking how mining works coal and mineral production the cause of equipment failures focused improving! Across commodities, geographies, and most mining companies should strongly consider implementing down, miners focused... Mila miliardi di dollari digitization, in particular, offers several useful approaches them rapidly questions... 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