In a challenging 2024 marked by declining coal prices and adverse geological conditions, our Australian longwall client achieved a remarkable 33% lift in run-of-mine production—without adding resources or capital.
So, how did they do it?They focused on three core principles that unlocked hidden capacity:
Focus: Honing in on the most critical constraints to system throughput;
Alignment: Synchronizing departments through clear, visual performance metrics and KPIs;
Psychological Safety: Creating a culture where everyone feels empowered to speak up, take initiative and innovate.
From the Executive General Manager’s year-end message:
“We have unlocked 33% of hidden capacity simply by appropriately aligning the business.”“In 40 years of operation, it is now operating as efficiently as it ever has.”“Recent visitors commented that the standards here are some of the best they have seen.”
Since 2000, in over 90 interventions across 4 continents, in all types of mining (surface and underground) clients have provided similar praise.
This transformation went beyond productivity gains; it created “superflow in a spirit of calmness” and fostered a fun, safe workplace—It’s a game-changer that most mines only dream of achieving.
Ready to unlock hidden capacity—without risky capital outlays or operational disruptions—and make work fun again?Let’s talk.

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