Increased hoist efficiency from 70.9% to 78.3%, average daily tonnes lifted from 3559t to 4663t, and improved average daily revenue by $125,000.


The tools being used for this case study are as follow

  • APC Productivity
    Analysis (PA)
  • Instrumented Hoists tachometer and slack rope monitoring
  • IP infrastructure
    and cameras
  • Visualisation Screens

Our client, Glencore Copper Africa, engaged APC to investigate a hoisting shaft that had an ageing infrastructure and performance below expectations.  Reporting on the hoisting activity was manual and the information was inaccurate and 24 hours old.   The choices were to perform a substantial upgrade of the hoist, or to improve the performance of the existing hoist, while not materially impacting production.

APC determined that the performance of the existing hoist could be improved, by deploying a real-time monitoring and tracking system that provided visibility, stoppage recording, and automated communication.   The design criteria were rapidly installable, highly visible, and conducive to cultural change and sustainability.

Once the hoist was instrumented, APC PA was deployed to analyse the fundamentals of performance: cycle times, maintenance and operator influence.   Through the visual management of hoist movement:

  1. Night shift performance was improved
  2. Statutory and non-statutory was observed, and
  3. Driver breaks were reduced to 20 minutes

The second phase was to improve the “Control Room Culture” – by providing tools to allow the rapid identification and response to stoppages. APC PA detects stoppages outside tolerance, and prompts for a reason.  These reasons were standardised across the sites, allowing the development of a common response to issues.

Hourly reports are distributed to key personnel to track manager notification, actions, and resolution of downtimes.

Key Achievements


Managed driver breaks to regulation time adding additional 20 minutes per day of hoisting time.


Increased skip cycle time from 19 skips per hour to 21 skips adding additional capacity of 20 hours x 2 skips x 12 tons = 400 tons per day.


Reduction of Mechanical unplanned maintenance by 40%