Question 1

How can I increase mine production without capital expenditure (Capex)?

Accepted Answer

Most mines have already shown, on their best days, that they can produce well above their average. The gap comes from interdependence and variability, which affect how work flows between departments. We help you find the constraint that sets mine-wide output, protect it with buffers and spare capacity, and coordinate around it in a daily Flow Room. At an Australian longwall mine, annual production rose from a 2.4 Mt average to 3.2 Mt in 2024, with no additional people and no or very little capital.

Question 2

Is the Flow Room suitable for underground and open-cut operations?

Accepted Answer

Yes. The method has been used in longwall and bord-and-pillar coal, deep-level gold, platinum stoping, and open-cut iron ore, copper and diamond operations. The principles stay the same; the constraint, buffers and triggers are specific to each site.

Question 3

How is this method different from that of other mining consultancies?

Accepted Answer

We treat the mine as one system and start from its constraint. The Flow Room adds a short daily coordination layer to your existing management operating system instead of replacing it, and your own people run it. The first step is a contained, reversible test in one area.

Question 4

What results can I expect?

Accepted Answer

Every site is different. Counting Arrie van Niekerk's earlier work and ours, the method has been applied in more than 90 mining interventions, and output gains have typically been 10 to 40 per cent with the same resources. One Australian longwall operation lifted annual production from a 2.4 Mt average to 3.2 Mt in 2024, with no additional people and no or very little capital. Clients also report better and faster decisions, less firefighting and better alignment and prioritisation across production, maintenance and planning.

Question 5

How can I learn if this approach suits my site?

Accepted Answer

Run the Best-Day Diagnostic on six months of daily production data; nothing leaves your browser. Or book a 30-minute conversation.

Question 6

What is the Theory of Constraints (TOC) and how does Stratflow use it in mining?

Accepted Answer

The Theory of Constraints (TOC), developed by Eliyahu Goldratt, is a management philosophy stating that any complex system (like a mine) has at least one constraint (or bottleneck) that limits its overall performance or throughput. Stratflow applies TOC by: * Identifying the Constraint: Finding the specific part of the mining process that limits overall production. * Exploiting the Constraint: Making sure the bottleneck operation is utilised to its maximum potential, minimising downtime and optimising its performance. * Subordinating Everything Else: Aligning all other processes and departments to support the bottleneck's performance. Non-bottleneck activities should operate in a way that ensures the bottleneck is never starved of input or blocked by output. * Elevating the Constraint: If necessary, investing resources (time, money, effort) to increase the capacity of the bottleneck itself. * Repeating the Process: Once a constraint is addressed, a new one may emerge elsewhere in the system, and the process starts again. Stratflow uses TOC to shift focus from balancing capacity everywhere (which is often impossible and leads to variability) to creating a smooth, optimised flow through the constraint, making the entire system more productive and predictable.

Question 7

We already have a daily "War Room." How is Stratflow's "Flow Room" different?

Accepted Answer

While both are central meeting spaces, the Flow Room is a significant upgrade designed for focus and systemic action: Traditional War Room Issues: Often display a vast amount of data and KPIs, potentially overwhelming managers and diluting focus. Some metrics might even conflict. This can make it hard to quickly identify the most critical issues impacting overall production, leading to delays in a time-sensitive environment. Stratflow Flow Room: Focused Information: Uses real-time visual management (screens/boards) displaying only the critical information related to the system's constraint, the flow through it, and the status of protective buffers. Uses colour-coding (e.g., red/green) for immediate understanding. TOC-Driven: Its structure and the data displayed are directly linked to managing the mine's bottleneck based on TOC principles. Cross-Functional Collaboration Hub: Designed as a "central nervous system," bringing together heads of departments, managers, and key employees daily. Built for conversation: Actively fosters teamwork, communication, and shared understanding across traditional silos and hierarchy levels. Focuses on the quality of conversations to drive solutions. Proactive Focus: Enables teams to identify potential issues and early warning signals before they disrupt flow, shifting from reactive firefighting to proactive problem-solving.

Question 8

How is a Stratflow Flow Room implemented? Is it complex?

Accepted Answer

The implementation process is straightforward and builds on the meetings and systems you already have: Dedicated Space: Identify a suitable room for daily meetings. Visual Management Tools: Install large screens or whiteboards. Data Integration: Integrate real-time data feeds for critical flow metrics (focused on the constraint and buffers). Daily Meetings: Establish short daily meetings (usually about 30 minutes) with representatives from key departments (HODs, managers, key employees). Meeting Focus: Review performance against targets, identify bottlenecks/potential issues, and collaboratively plan actions for the next 24 to 48 hours. Facilitation: Stratflow facilitates the initial setup and embedding of the TOC principles and the conversation practices within the Flow Room process.

FREQUENTLY ASKED QUESTIONS

How can I increase mine production without capital expenditure (Capex)?

Is the Flow Room suitable for underground and open-cut operations?

How is this method different from that of other mining consultancies?

What results can I expect?

How can I learn if this approach suits my site?

How long does an engagement take?

How is an engagement priced?