How an AI-native MRO intelligence layer closed inter-site inventory gaps, cut emergency procurement 47%, and released $26M in working capital across five mine sites in 10 weeks.
One of the world's largest gold and copper producers, operating five mine sites across three continents.
The organisation runs open-pit and underground mines in North America, Africa, and the Pacific, managing haul truck fleets, SAG and ball mills, primary and secondary crushers, draglines, and associated processing plant infrastructure. At deployment, its combined Inventario MRO was approximately $120M across five site storerooms and two regional distribution warehouses. Five years of rapid production growth had left each site running its own SAP ECC instance with no enterprise-level MRO visibility, no consolidated demand intelligence, and gestión de piezas de recambio processes that had not kept pace with the network it now needed to support.
How a ~$26M working capital release started with five MRO visibility failures no ERP upgrade could fix.
Five SAP ECC instances applied criticality scoring at site level using different criteria, with no cross-site normalisation. Cost: a SAG mill or primary crusher stoppage ran $600K to $1.5M per day in lost production.
Two sites had road-only access during wet season; OEM lead times reached 12 to 18 weeks. Reorder points had not been updated since ERP go-live as fleet utilisation and supplier performance shifted. Cost: unplanned stoppages on critical wear parts.
Site teams had no visibility of inventory held at peer sites. An internal audit found 14 emergency orders in a single 12-month period placed for components already in surplus at another site within the same network. Cost: unnecessary airfreight and expediting at 30 to 60% premium.
Planned shutdown parts lists were cross-referenced manually. Missing or obsolete items were typically identified 2 to 3 weeks before execution, by which point only emergency procurement channels remained available. Cost: one prior shutdown cycle incurred 3 emergency events and a 2-day overrun worth approximately $2.4M in lost production.
340+ line items across the five sites were flagged as potentially obsolete or at obsolescence risk on aging fleet assets (Caterpillar, Komatsu, Metso, Sandvik). No certified alternates were recorded. Cost: unqualified substitutions made under parts-availability pressure at site level, with no enterprise compliance visibility.
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Responsible for uptime on high-value assets where a single stoppage costs $600K or more per day.
Gestión de Adquisiciones MRO across multiple sites, reducing emergency spend and airfreight premiums.
Accountable for planned shutdown execution and parts availability weeks before mobilisation begins.
Managing multi-instance SAP MRO environments and looking to add intelligence without replacing the ERP.
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