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Case Study

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US$73m of improvement ideas implemented through operational improvement for an open-cut gold mine

Business challenge

Our client needed to improve productivity and overall operations while factoring in tough mining conditions, high turnover of the management team, and high operational downtime.


An open-pit gold miner had just completed a transition to owner-mining, and faced many operational challenges including old mining equipment and a high-maintenance processing plant.

Unit costs were under severe pressure: fixed costs increased by 100% following the transition; rising fuel and power costs; main pit getting deeper and haul distances longer.

Business impact


of improvement ideas implemented


return over target (US$52m cash benefit in 12 months delivered, against the diagnostic target of US$26m)


in long-term improvements at financial year end with the improvements incorporated into the new financial and operating budgets


increase in tonnes mined (67k tonnes/day to an average of 94k tonnes/day)


Top Line Solution

Improve productivity and overall operations facing numerous challenges

Review and optimise Capex spend

Increase truck operating hours

Reduce operating downtime in mining and processing

Establish client business improvement capability, and transfer skills and continuous improvement processes to a dedicated client team

LeftMining and MetalsLeftContinuous Improvement