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Case Study - Reducing Tyre Damage by over 50% via Lean 6 Sigma


A large gold mine was experiencing significant levels of tyre damage, leading to early tyre failure on dump trucks, and reduced gold output.

1. We graphed the results

On a Process Behaviour Chart, to understand if the problem was systemic. The way the problem manifests (systemically or not) determines the most efficient and effective improvement approach to adopt.

2. We identified apparent root cause hypotheses

To highlight the key potential underlying causes.

3. We tested the root cause hypotheses using statistical methods to identfy the actual root causes, and then solutionised the root causes

By correlating (and / or using other statistical methods) the hypothesised causes to the problem to ensure proven causality, when we solutionised we were confident of success.

4. We implemented and measured

We adopted the solution and continued adding data to the Process Behaviour Chart established in Step 1., to ensure changes were effective, and sustained.

5. Result

Tyre damage was reduced by 50%, a $4m+ benefit per annum!


Delivery to Plan


Tyre Damage Reduction


ROI from aorist consultancy, training and coaching

Businesses typically benefit from a 50 - 100+ times rate of return, when measuring the cost of an aorist Lean 6 Sigma or Systems Thinking / Systems Dynamics Simulation training course and coaching against the benefits derived from applying it the very first time in their business.