Increasing Daily Mine Production at a High-Grade Iron Ore Mine in Canada
How focused coaching, real-time decision support, and aligned execution helped a high-grade iron ore mine achieve a 20% uplift in mine production.
Background
A North American iron ore producer operates a well-established open-pit mining operation in Canada. The site produces more than 6 million tonnes of high-grade iron ore concentrate annually through its integrated open-pit mining and onsite processing facilities. With growing global demand for premium ore, the operator identified the need to continuously improve efficiency and production reliability. The company recognized that even marginal gains in daily output could deliver significant value, particularly in a cost-sensitive and competitive market.
While the operation had an experienced workforce and strong infrastructure, variability in shift performance and inconsistent handling of interruptions limited daily production. Decisions were often reactive, and the connection between field execution and production outcomes wasn’t always clear. To address these challenges, the operation partnered with Outliers Mining Solutions to deliver a focused improvement program centred on real-time dispatcher coaching, Short Interval Control (SIC), and structured shift execution support.
The Challenge
Before partnering with Outliers, the operation was experiencing several systemic issues that were limiting its ability to maximize production:
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- Frequent production losses were occurring due to unaddressed shift-level interruptions and a lack of standardized response mechanisms.
- Limited visibility into real-time bottlenecks was hindering timely decision-making and shift adjustments.
- A disconnect between field execution and dispatch priorities was resulting in fragmented coordination and reduced shift productivity.
These issues combined to create a cycle of inconsistent performance and underachievement in daily production targets.
While the operation had an experienced workforce and strong infrastructure, variability in shift performance and inconsistent handling of interruptions limited daily production. Decisions were often reactive, and the connection between field execution and production outcomes wasn’t always clear. To address these challenges, the operation partnered with Outliers Mining Solutions to deliver a focused improvement program centred on real-time dispatcher coaching, Short Interval Control (SIC), and structured shift execution support.
Our Approach
Outliers Mining Solutions deployed a hands-on, coaching-driven program tailored to the client site’s operational needs.
The initiative focused on both people y process:
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- Trigger/response action plans were developed for high-impact operating scenarios to improve material flow and reduce lost time at the crusher.
- 1-on-1, scenario-based coaching sessions with dispatchers and supervisors-built confidence in real-time decision-making and reinforced accountability on shift.
- Training focused on core execution levers including interruption management, effective system use, shift communication, and standard work practices.
- SIC dashboards were introduced to improve visibility of in-pit fleet performance and equipment breakdowns, supporting faster shift-level adjustments.
- Lean Board KPI tracking was rolled out on a shift-by-shift basis, enabling supervisors to connect daily performance to operational goals.
- A site-specific Operations Playbook was developed to document best practices and provide a foundation for ongoing improvement.
The Outcome
The client operation sustained a 20% improvement in average daily mine production across the majority of the project scope, driven by more consistent shift execution and stronger in-seat decision-making.
Dispatcher performance improved significantly, with crews demonstrating stronger execution and faster adaptation to real-time challenges. The introduction of visual management helped supervisors and frontline leaders better understand how to influence production outcomes, while the structured coaching reinforced new behaviors across all crews.
Even areas not directly addressed, such as road quality, truck speeds, and shift transitions, surfaced as opportunities for improvement. This reflects a key strength of the approach: creating visibility that encourages teams to question existing practices and pursue further gains.
Key Takeaways
This engagement reinforced a simple truth: operational change doesn’t require perfect conditions. It requires the right focus, commitment, and support.
Meaningful progress was achieved by meeting the team where they were and focusing on what mattered most. By prioritizing real-time decision-making, aligning expectations across all levels, and coaching dispatchers directly in their working environment, Outliers helped the operation unlock measurable performance gains and lay the foundation for long-term, site-driven improvement well beyond the initial project scope.
Let’s Talk Results
Real operational improvement starts on shift.
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