This white paper explores how a struggling brownfields mining infrastructure project was turned around through the focused application of LEAN construction principles. The project involved replacing production blocks nearing depletion through a two-phased approach: establishing access and underground infrastructure in Phase 1, followed by surface construction and dewatering in Phase 2. By the time the project team took over at the start of Phase 2, the project was already behind schedule and over budget. Early challenges included flooding, unplanned underground conditions, and legacy delays from Phase 1.
The mine’s production continuity required fixed deadlines, necessitating a new approach to execution management. Traditional project controls proved reactive and insufficient for managing the interfaces, risks, and external disruptions involved. LEAN construction principles were introduced to create structure, reduce waste, and improve coordination between teams.
Through the use of visual planning models, look-ahead schedules, and a strong focus on interface management, the team was able to plan ahead, respond quickly to risks, and streamline construction. The project was delivered on time and within budget despite ongoing pressures such as sabotage, theft, and scope creep. Critical decisions, like replacing a traditional substation with a prefabricated E-House, enabled faster delivery with better quality control.
While LEAN was more challenging to apply in underground works due to limited stakeholder buy-in, it proved highly effective in managing surface works, identifying early risks, and maintaining project momentum. The project not only met technical and schedule targets but also contributed to ongoing mine operations and job preservation in the surrounding communities.
This paper outlines the approach, outcomes, and lessons learned from the project, demonstrating how LEAN Construction, when appropriately tailored, can improve outcomes on complex capital projects operating under pressure. While this case study focuses on a brownfields mining environment, the principles and practices applied are relevant to a wide range of complex infrastructure projects that demand tight coordination, real-time decision-making, and efficient resource management.
