Note: Anonymized operational data. Selected excerpts shown; confidential details removed.
Report Snippet: Copper Smelter (Ops-only)
Report Content
Executive Summary
What we analyzed: Five processes end-to-end; 60+ ops metrics; 35+ internal benchmarks; 85+ interdependencies; ~95% data coverage with a 278-metric dictionary.
Headroom (based on ops data): +12–15% system throughput when sequenced across reliability, thermal efficiency, and cycle stability. Key KPI lifts: Recovery +2.9 pp (94.2%→97.1%), Energy +0.10 (0.68→0.78), OEE +14 pp (72%→86%).
Indicative financial outcome: $20-30M/yr within 12–24 months.
Immediate ops priorities (quick-wins + control discipline):
- ◦Maintenance reliability: optimize scheduling; launch predictive condition monitoring on bottlenecks.
- ◦RMM stability: tighten Raw-Material Mix via SPC/APC; standardize converting cycles.
- ◦Energy management: stand up real-time Energy Management System (EMS).
Primary Performance Gaps
| Process/Area | KPI | Current | Benchmark | Gap | Primary Drivers |
|---|---|---|---|---|---|
| System-wide | OEE | 72% | 86% | -14 pp | Planned/unplanned downtime; rate loss. |
| Raw-Material Mix (RMM) | OEE | 68% | 81% | -13 pp | Availability losses; feed mix variability (CV>12%). |
| Raw-Material Mix (RMM) | FPY | 89% | 94% | -5 pp | QC discipline; SPC not enforced. |
| Primary Smelting | Thermal Eff. | 68% | 78% | -10 pp | Heat-recovery gaps; combustion control. |
| Converting | Cycle CV | 18% | 8% | +10 | Pierce equipment availability; air/enrichment ratios. |
| System-wide | Energy Eff. | 0.68 | 0.78 | -0.10 | Furnace utilization; waste heat; gas over-consumption. |
| System-wide | Recovery | 94.2% | 97.1% | -2.9 pp | RM quality variability; control limits exceeded. |
Guardrails: Sequence execution to the data: 25 high-impact interdependencies (e.g., RM Quality → Recovery r²=0.67; Thermal → Energy r²=0.73; Maintenance → OEE r²=0.71) to prevent local optima and make wins stack.