Ok Tedi Mining Limited Maintenance Strategy Improvement

Ok Tedi Mining Limited Maintenance Strategy Improvement

Location: Western Province, PNG

Year: 2017-2018

Project Overview

The Ok Tedi Mine is an open-pit copper and gold mine in Papua New Guinea located near the headwaters of the Ok Tedi River, in the Star Mountains Rural LLG of the North Fly District of the Western Province of Papua New Guinea. The objectives of this project were to review and improve the current fixed plant planned maintenance strategies to enable delivery of current and future production forecasts.

Scope of work

Ok Tedi Mining Limited (OTML) engaged Holistic Asset Management to provide the resources and leadership to support the production objectives of the processing plant.

HolisticAM worked with OTML to identify and prioritise critical asset classes and processing systems to ensure ‘show stopping’ asset strategies were addressed as a priority.

HolisticAM mobilised senior asset management consultants from July 2017 through to July 2018 to conduct the improvement program that required:

  • Development of project plans and critical pathways
  • Development of draft work management processes and master data standards
  • Identification, location and verification of asset equipment and the development of a detailed equipment hierarchy,
  • Review, optimisation and creation of critical equipment strategies,
  • Review, modification and creation of BOM’s for critical assets,
  • Development of introductory reliability and change management training, and
  • Creation of SAP® master data load sheets for PRT’s, task lists, maintenance items, maintenance plans and bills of material.

Working closely with a workforce who are continually striving to improve and increase their knowledge of maintenance improvement methods enabled the creation of effective teams motivated by a common goal to reach the forecast production targets and availability KPI’s.

key deliverables

Over the period spent at site, HolisticAM was able to successfully engage with engineering, maintenance, reliability, operations and senior management employees to provide a thoroughly reviewed planned maintenance strategy on critical assets within the processing plant.

  • Maintenance strategies for critical assets optimised and developed using FMECA methodologies,
  • FMECA libraries of common asset classes and variances discovered within the plant
  • Detailed equipment structure for critical assets,
  • Grouped and resourced maintenance tasks,
  • Maintenance strategy task documents (PRT’s),
  • SAP® load sheets,
  • Before and after reviews of maintenance work orders and resourcing requirements,
  • Summary reports detailing changes to critical maintenance strategies, and

Detailed closeout report providing project insights and areas for continued effort and improvement.