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      A leading integrated non ferrous metal producer with operations spanning underground mines, smelters, beneficiation plants, and captive power plants was facing pressure to stabilise monthly production and achieve aggressive cost targets. Challenges in short term planning, limited digital enablement, and sub optimal power optimisation were impacting production consistency and cost performance.

      KPMG in India was engaged to deliver a focused production improvement and cost reduction programme-helping institutionalise agile execution, strengthen operational planning, and enable data driven decision making across operations.

      The challenge

      The client operated in a complex, asset‑intensive environment with multiple operational constraints:

      • Short-term work planning and equipment scheduling inefficiencies causing production delays
      • Smelter operations heavily reliant on operator experience without digital twin support
      • Ineffective power load balancing between renewable energy sources and captive power plants
      • Need for agile execution models to stabilise monthly production and cost performance
      • Simultaneous pressure to improve output while reducing operating costs

      The client required an integrated, data‑driven approach to improve production reliability and cost efficiency across the value chain.

      Our approach

      KPMG in India adopted an diagnostic and execution‑focused transformation approach, integrating operational excellence, digital solutions, and governance.

      Operational diagnostics

      Assessed production planning, utilisation, and performance bottlenecks

      Identified key constraints across mining, smelting, beneficiation, and power operations

      Prioritised improvement levers aligned to finished goods production stability and cost performance.

      Operations, maintenance, and reliability intervention

      Lean and TPM-based initiatives to improve asset availability and utilisation

      Structured production and maintenance planning to support steady monthly output

      Process discipline introduced across operations to sustain improvements.

      Digital enablement and advanced analytics

      Digital Planning Tool for advanced planning and short-interval control

      Real-time dashboards using OSI PI

      Digital Twin for key operations

      Advanced Planning and Scheduling System (APASS) to align operations and maintenance.

      Cost reduction and power optimisation levers

      Digital tools to optimise power consumption and reduce energy costs

      CPP flexibilisation to improve renewable power absorption

      Governance mechanisms to track initiatives and sustain benefits.

      Operational diagnostics

      Assessed production planning, utilisation, and performance bottlenecks

      Identified key constraints across mining, smelting, beneficiation, and power operations

      Prioritised improvement levers aligned to finished goods production stability and cost performance.

      Operations, maintenance, and reliability intervention

      Lean and TPM-based initiatives to improve asset availability and utilisation

      Structured production and maintenance planning to support steady monthly output

      Process discipline introduced across operations to sustain improvements.

      Digital enablement and advanced analytics

      Digital Planning Tool for advanced planning and short-interval control

      Real-time dashboards using OSI PI

      Digital Twin for key operations

      Advanced Planning and Scheduling System (APASS) to align operations and maintenance.

      Cost reduction and power optimisation levers

      Digital tools to optimise power consumption and reduce energy costs

      CPP flexibilisation to improve renewable power absorption

      Governance mechanisms to track initiatives and sustain benefits.

      The impact

      The programme delivered tangible improvements across production and cost performance:

      receipt_long

      Increase in Metal in Concentrate

      percent

      Highest ever refined metals production with ~2% increase

      assignment

      Cost of Production decreased by ~6% (dollar terms)

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      Improved production planning, power optimisation, and digital adoption

      summarize

      A sustainable execution backbone established across operations

      Key Contact

      Amit Bhargava
      Amit Bhargava

      National Leader, Metals and Mining

      KPMG in India

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