Case Study



We delivered immediate bottom line improvements and created disciplined site-wide, continuous business improvement programs that focus on loss and failure elimination for long-term sustainability.


Underground Metals Mine, Australia.


Our client required support to establish a business value improvement methodology and mechanisms to reduce costs. This extended to include:

  • Opportunity identification
  • Improvement realisation and management
  • Benefits capture
  • Reporting

To implement a continuous business improvement discipline onsite, our Xenco consultants:

  • Engaged at all levels of the organisation to workshop and continuously capture ideas for business improvement
  • Identified productivity as a key deficiency and put measures in place to ensure bottlenecks were understood and addressed.
  • Implemented a methodology to prioritise initiatives based on risk and value, and tracking and reporting to focus on the most important items
  • Established routines for communication updates to maintain focus on implementation and ensure sustained benefits
  • The initiatives developed by Xenco delivered an overall returned business value of over $10M annually.
  • As part of this process, multiple contracts were renegotiated and signed off, resulting in >$0.7M savings.
  • A major program was initiated to re-establish and improve the metallurgical performance of the plant; the program’s Net Present Value (NPV) is estimated to be over $40M and led to an internal rate of return (IRR) greater than 100%.
  • Major bottlenecks were identified and addressed through operating discipline and the application of overall equipment efficiency (OEE) and Lean principles.
  • Increased recovery at 75.3% Metal (previous quarter 71.3% Metal) as the benefits of the metallurgical improvement program are being realised.

“Xenco offered a unique service – their ability to leverage their business acumen and extensive operational experience allowed them to provide the support we needed to unlock value and reach our goals. They challenged the status quo and drove change by starting with the ‘Why?’. The value delivered by Xenco was unparalleled; they were able to tailor solutions to fit our company values and meet corporate objectives in a time and cost-effective manner.”