Visiting Morupule Coal Mine (MCM) is always something I look forward to. I like the country very much – especially the people, whom I find friendly, respectful and eager to learn. And there is nothing more wonderful than being in Botswana when it rains (and nothing more challenging when you are there in mid-summer, outside and doing a lot of walking)!
MCM is situated on the outskirts of Palaye, Botswana. Production of washed and thermal coal started in 1973, with Botswana Power Corporation (BPC), which is supplying power to Botswana situated next door to the mine, its main customer. MCM started in 2010 with implementing a customised version (tailored to coal mining) of the 20 Keys System for Continuous Operations Improvement. The senior management team committed to implementing a systemic and systematic approach for improving operations and have actively supported it since that time. Their commitment to such a system, over a long period of time, is an example of what is meant by having senior management support.
Matthews Bagopi, executive committee member, with a full plate of things to do as MCM Business Development Manager, is unwavering in his belief and commitment to the system. Reporting to him is Lapologang Lletshwenyo (Laps) who does an excellent job facilitating and supporting line management with the implementation. Laps’ role is an important one, as ODI’s experience, based on many implementations, indicates that without such internal focus and support of the implementation, improvement is, at best, sporadic and very difficult to sustain.
Since 2010 a number of week long visits are done every year to support their implementation of continuous operations improvement. The weeks differ in terms of objectives – sometimes support is given with a specific element (which is called a Pillar), for example Maintaining Machines and Equipment or Cost Efficiency and other times the 33 onsite teams are visited during which progress with priority Pillars and next steps for improvement are discussed.
These teams represent all people at the mine, from underground mining sections and underground support functions, the processing plant, all engineering functions, as well as all other surface supporting functions (Administration, Geology, Ventilation, Planning, HR, SHE, Purchasing, Clinic, Stores, and others). The Pillars of the MCM Business System are implemented in all these functions, tailored to the particular function. Engaging all people, from all organisational functions, is a critical success requirement for sustainable operations improvement.
With the last visit, during the first week of July 2019, the emphasis was on progress with three issues:
- Short interval control measures, with triggers for action when deviations are observed. When triggers are observed, active supervision and management support, in the workplace, are important to quickly address issues
- Improving cost effectiveness, that is, focusing on the monetary aspects of cost per ton as well as productivity and efficiency of work. MCM has excellent measures for managing cost, which is cascaded down to each team with aligned measures to keep the focus of everyone on managing cost. In addition, having time standards for tasks (in all functions, including supporting functions), with measurements and analysis of actual times vs. standard, support with the efficient use of time
- Implementing cross functional small group activities (SGAs) for operations improvement. There is a saying that “most of the waste in the value stream, from suppliers to customers, is between the links in the value stream”. The focus at MCM is therefore to ensure that teams work effectively together and quickly address issues, from mining coal to delivering energy to customers.
It was energising to see the progress made, and also to meet old friends again. At the feedback session on the Friday commitment was expressed by the team for focusing on next steps.
Come and join ODI at their conference on 29 August 2019, where Laps will make a presentation on their journey to operations excellence. To read more about ODI’s conference on 29 August 2019, click here.
My privilege to award a trophy at the end of the week, to the best team
Most recent winners, the SHE team. Statistics indicate that MCM is also one of the safest mines in Africa!
Previous winners, Purchasing; implementing excellent cross functional SGAs
Previous winners, Accounts; actively participating with cost savings, also through cross-functional SGAs
Author: Johan Benadie – Director at ODI