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Contents
Executive summary
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Conclusion 22
Executive summary
Mining and metals companies have
seen unprecedented growth in capital
projects investments due to rising
commodity prices, with metals and
mining expenditures peaking at more
than $140 billion1 in 2012.2 Even
with a recent downturn in commodity
prices, investments will remain based
on long-term demand for minerals and
metals, which continues to be driven by
economic growth and social development
throughout the world. An estimated
$1.5 trillion is projected to be spent
globally on metals and mining projects
through 2025.3
Projects are growing in scale and
complexity, based on geological factors,
the remoteness of project sites, limited
available talent, construction labor
constraints and increasing infrastructure
requirements. Expectations of superior
safety and a focus on environmental
concerns will continue to grow regardless
of location, but country risks will rise
as companies carry out the search
for minerals to higher-risk regions.
Host-country expectations on local
content and investor expectations are
intensifying the sustainability focus. In
addition, price volatility during project
execution can abruptly change cash
flows and market perceptions on the
rate of return/value of a project.
Figure 2. Distribution of capital projects for mining and metals companies surveyed.
Figure 3. The majority of respondents are not consistently delivering against their own targets.
Leading performers
attributes and advantages
Accenture analysis of the survey data shows multiple
attributes and capabilities set leading performers apart
from other organizations. A group of leading companies
outperforms the rest in meeting their own project targets
on safety, environment, sustainability, cost, schedule,
quality and delivery of reliable production capacity.
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Attributes
Higher priority on effective delivery
Not surprisingly, companies that achieve
a higher proportion of on-time, onbudget delivery for their projects assign
a higher priority to project delivery
capabilities and focus. Ninety percent
of leading companies cite effective
project delivery (in regards to established
project goals of safety, environment,
cost, schedule and meeting throughput
design) as critical compared to 71 percent
of companies in the rest of sample.
Well-developed culture
Leading companies are more confident of
their culture of project delivery excellence
(Figure 8), and a 42 percentagepoint spread separates leaders (80
percent) from others (38 percent). A
well-developed culture does not rely
on having a large owners team, but
rather an effective and experienced
team of project collaborators. A welldeveloped culture needs to be infused
with capabilities in risk management,
superior project management, stagegating and peer-review processes. A
strong program management office
needs to integrate activities with EPCs,
EPCMs and construction companies.
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Advantages
Partly as a result of some of the attributes
described earlier, survey analysis finds
that the leading group experiences:
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Follow a field-tested
planning tool for the
validation of front-end
loading activities
Front-end loading should occur through
a well-established, stage-gate phasing
(Figure 9). Team members need to meet
guidelines for each stage, identify gaps
and address them in a peer-review
process before moving to the next phase.
A highly disciplined approach clarifies
engineering needs, and leads to more
accurate cost and schedule estimates.
Multiple methodologies for validation
of the quality of the stage-gate process
exist, including the Project Definition
Rating Index (PDRI) for industrial
projects. Independent Project Analysis
(IPA), Inc., is also well known for its
methodology. The choice of tool is
not as important as solid commitment
to follow a tested methodology.
For megaprojects, field-tested frameworks
can help save hundreds of billions of
dollars. A study analyzing more than
100 organizations that followed PDRI
methodology, for example, showed
leading companies were able to keep
costs four percent below budget,
compared to the rest of the sample,
which went six percent over budget.
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Implement a rigorous
approach to risk
management
Assembling a cross-functional group helps
to identify a wide range of risks, and the
ways in which risks interact and magnify
the adverse consequences. A diagnostic can
help assess if an organizations capabilities
meet the level of complexity of the project.
Proactively managing risks, such as those
listed in Figure 10, helps reduce the number
of problems, claims and scope changes.
Conferring regularly with contractors
and suppliers also can help project
owners manage a wide range of risks.
Figure 9. Typical capital project phases, with the first three parts of front-end loading (FEL).
Source: Accenture
Human capital
Management of contractors
Limited resources for effective oversight
of EPC firms and contractors, who also are
experiencing human capital shortages
Difficulty of managing non-mining
components, such as building infrastructure
in remote areas
Production ramp-up
Failure to consider production issues to
bring products to market at early stages of
the project design
Risk mitigation of major production
problems not done early enough
Delay in setting up the IT infrastructure and
applications
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Employ smart
organizational design
One of the reasons cost overruns occur is
that highly paid, highly technical people
perform a large amount of transactional
work that could be outsourced.
Companies may choose to outsource
procurement, for example, and obtain a
volume discount of up to 10 percent by
grouping purchases for multiple projects.
Another provider might be contracted
to manage order issues, bar coding and
tracking, along with links for maintenance
tracking, and for payments and credits.
Also consider roles that can be done
remotely (e.g., from a centralized project
office versus those required at a site). Tasks
that must be done at the site, however,
may need fly-in, fly-out (FIFO) talenta
growing trend.
Consider innovative
business models
Given chronic cost overruns, project
owners need to consider creating new
models for project delivery. One Canadian
mining executive, for example, questions
the validity of the EPCM model. He
foresees a model that brings together a
few highly competent firms with distinct
specialties: engineering, construction
and management consulting. The
model calls for seamless integration of
information and communication among
these key players, as well as taking
advantage of the best skills of each
stakeholder to meet the project goals.
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Virtual tools
Virtual tools, including next-generation
portals, help to bring project teams
together, enabling collaboration,
knowledge management and learning.
Knowledge management
Due to high turnover, knowledge
management systems are essential.
Formal processes need to be implemented
and documented rather than continuing
to rely on internal knowledge of
people who are nearing retirement.
Performance management
Integrated information systems and
KPIs give project managers a stronger
handle on the cost of mine development
from region to region, and among
product groupings. This data can
result in leading practices, supplier
rationalization and cost reduction.
Conduct operator
training in parallel with
construction
Operator training ideally should be
conducted ahead of the early stages
of start-up and commissioning
functions during the intermediate-tofinal stages of construction. As noted
in the Recommendation section on
managing scarce talent, simulations
use advanced technology to give
operators a realistic look at what
they will be doing on day one.
Eliminate manual
processes whenever
feasible
Checking equipment for the purposes
of commissioning provides an example
of how manual procedures slow down
the process, adding to costly delays.
Technicians tend to manually enter data
onto sheets that is manually re-entered
into a system at the site office, and then
manually checked against drawings. By
segregating technical from transactional
activities, project teams can implement
more remote services to make better use
of scarce talent at the site.
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Conclusion
Throughout the project life cycle, keep the end
objective in mind
Comprehensive approaches are required to manage the increasing
scale and complexity of capital projects. The traditional
project management focus needs to be broadened well beyond
aspects of engineering and procurement. Todays projects call
for increased focus on governance, human capital strategy,
and integrating information systems with business partners
and operations. Given the severe talent squeeze, finding the
best resources to execute a companys capital projects is
critical, and coordination among all partners is essential given
the cost and complexity of multibillion-dollar projects.
Mining and metals companies need robust solutions. It helps to
look at vast projects with the end in sight, and then methodically
break them into sub-projects that can be managed in pieces
to address the risks at each stage. At a high level, some of the
ways to do this include improving front-end loading, addressing
project gaps and monitoring the project after objective
peer reviews. A strong project management organization
is essential for megaprojects with multiyear horizons.
Addressing cost and time objectives of capital projects is a
prime opportunity to achieve competitive advantage. Ideally,
capital projects should be run as high-stakes businesses with
targeted objectives, clear delivery strategies and careful
monitoring to track progress toward high performance.
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Reference
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About Accenture
Accenture is a global management
consulting, technology services and
outsourcing company, with 257,000
people serving clients in more than
120 countries. Combining unparalleled
experience, comprehensive capabilities
across all industries and business functions,
and extensive research on the worlds
most successful companies, Accenture
collaborates with clients to help them
become high-performance businesses and
governments. The company generated net
revenues of US$27.9 billion for the fiscal
year ended Aug. 31, 2012. Its home page is
www.accenture.com.
john.e.lichtenstein@accenture.com
12-2375 / 02-5527