Mining & Metals
More tons, lower cost per ton, no new capital.
From underground extraction to smelting and steel, we work alongside mine and plant teams to raise equipment availability, close production shortfalls, and build the operating discipline that holds output.
Client results
What USC has delivered in Mining & Metals
The headline result from 14 Mining & Metals case studies. Each figure comes from a separate engagement, so they should not be added together.
Financial results
$1.2M+in annual savings realizedSouth American gold mine realizes $1.2M+ a year with employee-led improvementRead the case study $1.7Madded to gross marginSpecialty alloy maker adds $1.7M to gross margin and lifts equipment effectiveness 11%Read the case study $35Min implemented improvementsSteel mill delivers $35M in improvements with a new casting strategyRead the case study $260Min productivity gains in mining and crushingIron ore miner gains $260M in productivity through better drilling and blastingRead the case study $45Min benefitsSteel operation cuts scrap 30% for $45M in benefitsRead the case study
Return on investment
9.7:1return on investmentGold miner's highest-cost site becomes its lowest-cost, with a 9.7:1 returnRead the case study 14:1return on investmentCopper-zinc miner raises equipment availability 66% with a 14:1 returnRead the case study 11:1return on investmentPotash and phosphate producer raises total tonnes 15% with an 11:1 returnRead the case study
Operational results
24%increase in ore throughput over baselineGold producer raises ore throughput 24% with an operating system for mine and millRead the case study 47%increase in production meters drilled a daySilver miner raises daily production drilling 47% after a stalled switch to long-holeRead the case study 25%increase in blister copperCopper smelter raises blister copper output 25% with a shared daily scheduleRead the case study 23%reduction in mine cost per tonCopper mine cuts cost per ton 23% and mines 22% more tonsRead the case study 50%reduction in lost-time incidentsSteel products maker cuts lost-time incidents 50% with a new safety systemRead the case study 19%reduction in cost per ounceUnderground gold mine cuts cost per ounce 19% and raises production 22%Read the case study
Evidence and ideas for better operations
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Mining & Metals
$1.2M+in annual savings realized
South American gold mine realizes $1.2M+ a year with employee-led improvement
Read the case study →
Mining & Metals
$1.7Madded to gross margin
Specialty alloy maker adds $1.7M to gross margin and lifts equipment effectiveness 11%
Read the case study →
Mining & Metals
$35Min implemented improvements
Steel mill delivers $35M in improvements with a new casting strategy
Read the case study →
Mining & Metals
$260Min productivity gains in mining and crushing
Iron ore miner gains $260M in productivity through better drilling and blasting
Read the case study →
Mining & Metals
$45Min benefits
Steel operation cuts scrap 30% for $45M in benefits
Read the case study →
Mining & Metals
24%increase in ore throughput over baseline