OUR CASE STUDIES
ENGCONOMICS
SHOWCASE:
ROLL OVER PROTECTION STRUCTURE (ROPS)
2024
KEY CHALLENGE
Personnel safety while driving an LDV
PROJECT OBJECTIVE
Produce a lighter solution to the current market
SOLUTION IMPLEMENTED
DESIGN A ROPS THAT IS LIGHT AND COST EFFECTIVE
- Current ROPS on the market weights 140 kg
- Engconomics ROPS weights 97 kg
- FEM used to optimize the design
MANUFACTURING AND DISTRIBUTION
- Engconomics manufacture and distribute the ROPS in conjunction with industry partners
BUSINESS VALUE
Designed a ROPS that weighs 43 kg less than current market products, resulting in lower manufacturing costs
SHOWCASE:
Container Port Terminal performance improvement
2024
KEY CHALLENGE
A complex operational environment with constraints such as equipment downtime, procurement inefficiencies, and inconsistent team participation impacted the overall efficiency and effectiveness of terminal operations.
PROJECT OBJECTIVE
To enhance operational performance within a 100-day period by focusing on specific, measurable objectives. These included improving the availability and reliability of key equipment, streamlining procurement processes, and achieving ambitious movement targets.
SOLUTION IMPLEMENTED
Engconomics utilized the Rapid Results methodology, which empowered front-line teams to implement targeted interventions swiftly. The project involved:
- Reducing equipment downtime and recovering long-standing equipment issues.
- Introducing innovative solutions like flexi flippers and redesigned hydraulic fittings on spreaders.
- Enhancing procurement processes and spares capacity management.
- Providing ongoing training and development to address skills gaps.
- Engaging sponsors and stakeholders for enhanced support.
- Implementing flexible meeting schedules to accommodate shift patterns.
BUSINESS VALUE
The Rapid Results methodology led to significant improvements in operational performance:
- Reduced downtime for critical equipment such as Spreaders and maintaining stabilized Straddle Carriers availability.
- Recovered and optimized the use of RTGs.
- Improved stock level management for fast-moving items.
- Empowered teams with continuous improvement and adaptation skills.
- Created a foundation for sustainable gains and future scalability of successful practices.
SHOWCASE:
Underground mining (Vehicle fatigue analysis)
2024
KEY CHALLENGE
Premature failure of Laud Haul Dump (LHD) chassis
PROJECT OBJECTIVE
Determine asset life and optimal maintenance interval
SOLUTION IMPLEMENTED
DESIGN A ROPS THAT IS LIGHT AND COST EFFECTIVE
- Strain gauge measurements during mission
- FEA based on dimensional measurements
- Fatigue life (rain-flow counting and EN standards)
- Determine maintenance interval
BUSINESS VALUE
Prevented production losses due to unpredicted failures
SHOWCASE:
Rock winder Skip Redesign
2024
KEY CHALLENGE
Regular rock winder skip failures resulted in failure investigations that revealed various design flaws
PROJECT OBJECTIVE
Reduce maintenance downtime by designing a fatigue enhanced door and eliminate stuck skip door incidents with wet ore loads
SOLUTION IMPLEMENTED
Results
- Developed new monocoque skip door concept
- Designed unwelded skip level box using rolling elements bearings
- Designed locking arm and repositioned it to eliminate the bridle influence
- New bridle and chute designed to improve twist torque resistance by over 50%
- Reduced harmonic excitation possibility and provided a lighter stiffer chute
DISCIPLINE AND SOLUTION AGNOSTIC
First principle mechanical engineering design principles followed, and FEA applied to verify
BUSINESS VALUE
Reduced downtime excess of R5 million per day.
Ensured 18 ton per load upgrade target
SHOWCASE:
Railway system asset condition audit
2023
KEY CHALLENGE
Private Public Partnership (PPP) agreement requirement to audit asset condition
PROJECT OBJECTIVE
Determine the condition and risk of Remaining Useful Life (RUL) of the system not achieved
SOLUTION IMPLEMENTED
In conjunction with industry partners Engconomics implemented:
- Desktop data analysis
- Sampled physical asset inspections with 5 Likert scale assessments
- RUL Risk Python Model determining the probability of assets not meeting the RUL requirements
BUSINESS VALUE
Key assets have been identified as at risk of not meeting their required RUL, with recommended actions provided.
SHOWCASE:
MINING PROCESSING
2023
KEY CHALLENGE
- Inadequate control reduced throughput
- Challenge identified while improving equipment reliability
PROJECT OBJECTIVE
- Leadership alignment and prioritisation of strategic initiatives using a Techno Economic Model/Digital Twin of the plant
- Just in time experiential learning
- 100 day projects
SOLUTION IMPLEMENTED
DEVELOPED CONTROL ALGORITHMS
- Modelling
- Neural networks
BUSINESS VALUE
Reduced equipment downtime by 96%
Sustainable performance improvement through enhanced capacity and capability
SHOWCASE:
platinum smelter production improvement
2023
KEY CHALLENGE
Ageing smelter bottleneck in Platinum production chain
PROJECT OBJECTIVE
Improve production output to a P101 target
SOLUTION IMPLEMENTED
- Reliability engineering and processing optimisation
- Extensive modelling
- Digital twin solutions
- Change enablement through 100-day Rapid Results projects
BUSINESS VALUE
Production improvements of up to 5% have been achieved to date
SHOWCASE:
PULP AND PAPER MODELLING
2021
KEY CHALLENGE
Frequent shutdowns due to boiler fouling and evaporator scaling
PROJECT OBJECTIVE
Improve frequent shutdowns due to boiler fouling and evaporator scaling
SOLUTION IMPLEMENTED
DEVELOPED NEW ALGORITHMS
- Measure the amount / rate of fouling and scaling
- Slow down the formation rate
- First of its kind
DISCIPLINE AND SOLUTION AGNOSTIC
- Combined chemical engineering (UP) and mechanical engineering competency (Engconomics)
BUSINESS VALUE
USD11 million net profit improvement per annum
SHOWCASE:
UNDERGROUND PLATINUM MINING
2020
KEY CHALLENGE
Operational sustainability due to financial and market pressures
PROJECT OBJECTIVE
100-day project
Reduce unit production cost
SOLUTION IMPLEMENTED
MINING
- Reduced mining heights
- Improved BUH grade
- Increased monthly centares
- Improved equipment productivity and utilisation
- Reduced tip mining and construction time
ENGINEERING
- Reduced equipment downtime due to unavailable critical spares
- Reduced downtime due to machine damages
- Improved artisan utilisation
- Improved maintenance / work environment – reduced unplanned primary equipment breakdowns
BUSINESS VALUE
Improved unit production cost from 4th quartile to 2nd quartile of peer mines
SHOWCASE:
OPEN PIT DIAMOND MINE UNIT COST improvement
2018
KEY CHALLENGE
Production constrained by market, unit cost lagging benchmarks
PROJECT OBJECTIVE
Improve unit cost of production
SOLUTION IMPLEMENTED
- Implementation of Physical Asset Management Standards
- Change enablement through 100-day Rapid Results projects
BUSINESS VALUE
7% maintenance cost reduction
SHOWCASE:
POWER UTILITY FINANCIAL OUTLOOK
2018
KEY CHALLENGE
Major power utility with under- maintained ageing plant at risk of balance sheet impairment
PROJECT OBJECTIVE
Independent technical audit of major power utility long-term cash generating capability
SOLUTION IMPLEMENTED
TECHNO-ECONOMIC MODEL
- Modelling age reducing production capacities and increasing costs age of all stations
- Modelling EBITDA for various scenarios over 30-year period
BUSINESS VALUE
Balance sheet impairment decision informed
