Increased Availability Leads to Significant Additional Throughput

Increased Availability Leads to Significant Additional Throughput

The Challenge

A major mining operation faced fluctuating maintenance KPIs and unreliable availability of bottleneck equipment, constraining throughput and operational efficiency. The need for a data-driven, cross-functional solution was clear.

Our Solution

Using Falconi’s Asset Reliability & Management system, we deployed a step-by-step approach:

1. Define strategic maintenance goals and align them with shop floor operations.
2. Perform ABC asset analysis and assess current Asset Reliability.
3. Develop integrated plans: Maintenance Engineering, Planning & Control, Execution.
4. Train operational teams for successful rollout.
5. Monitor performance and execute fast-response countermeasures for deviations.

Key Objectives

• Connect critical production KPIs to open-pit operations.
• Engage all functional areas: Operations, Maintenance, Contractors, Technical Support, Planning.
• Identify availability drivers (e.g., blackouts, overheating, human error).
• Implement forecasts and action plans based on deviation analysis.
• Track savings from reliability improvement initiatives.

Results

• ✅ +4.6% availability increase for bottleneck equipment.
• 📉 Reduced KPI variability, signaling better process control.
• 💡 Forecasted savings tracked across specific initiatives.
• 📈 KPI performance improved month-over-month following two key interventions.

Impact: Improved availability directly enhanced production throughput — without extra capital investment.

Why It Worked

• Structured problem-solving using data and cross-functional collaboration.
• Real-time monitoring of maintenance KPIs.
• Actionable insights leading to timely corrective plans.

📘 Conclusion

This case proves that targeted improvements in equipment availability can unlock substantial hidden throughput. Falconi's integrated approach enabled sustainable gains, enhanced accountability, and long-term value.

‍