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Barrick Gold\'s Lean Journey - Presentation given at International AME Conference (2008)
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Dave Elliott, Continuous Improvement DirectorTrevor Krawchyk, Learning Organization Manager
Barrick Gold Corporation
Lean Lessons Learned
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Today’s Presentation
• Barrick’s Lean Journey:• Why and how we started• Our implementation strategy• The critical success factors• Summary • Q&A
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CAUTIONARY STATEMENT ON FORWARD-LOOKING INFORMATION
Certain information contained or incorporated by reference in this presentation, including any information as to our future financial or operating performance, constitutes "forward-looking statements". All statements, other than statements of historical fact, are forward-looking statements. The words "believe", "expect", "anticipate", "contemplate", "target", "plan", "intends", "continue", "budget", "estimate", "may", "will", "schedule" and similar expressions identify forward-looking statements. Forward-looking statements are necessarily based upon a number of estimates and assumptions that, while considered reasonable by us, are inherently subject to significant business, economic and competitive uncertainties and contingencies. Known and unknown factors could cause actual results to differ materially from those projected in the forward-looking statements. Such factors include, but are not limited to: fluctuations in the currency markets (such as the Canadian and Australian dollars versus the U.S. dollar); fluctuations in the spot and forward price of gold, copper or certain other commodities (such as silver, diesel fuel and electricity); changes in U.S. dollar interest rates or gold lease rates that could impact the mark to market value of outstanding derivative instruments and ongoing payments/receipts under interest rate swaps and variable rate debt obligations; risks arising from holding derivative instruments (such as credit risk, market liquidity risk and mark to market risk); changes in national and local government legislation, taxation, controls, regulations and political or economic developments in Canada, the United States, Dominican Republic, Australia, Papua New Guinea, Chile, Peru, Argentina, South Africa, Tanzania, Russia, Pakistan or Barbados or other countries in which we do or may carry on business in the future; business opportunities that may be presented to, or pursued by, us; our ability to successfully integrate acquisitions, operating or technical difficulties in connection with mining or development activities; the speculative nature of exploration and development, including the risks of obtaining necessary licenses and permits; diminishing quantities or grades of reserves; adverse changes in our credit rating; and contests over title to properties, particularly title to undeveloped properties. In addition, there are risks and hazards associated with the business of exploration, development and mining, including environmental hazards, industrial accidents, unusual or unexpected formations, pressures, cave-ins, flooding and gold bullion losses (and the risk of inadequate insurance, or inability to obtain insurance, to cover these risks). Many of these uncertainties and contingencies can affect our actual results and could cause actual results to differ materially from those expressed or implied in any forward-looking statements made by, or on behalf of, us. Readers are cautioned that forward-looking statements are not guarantees of future performance. All of the forward-looking statements made in this presentation are qualified by these cautionary statements. Specific reference is made to Barrick’s most recent Form 40-F/Annual Information Form on file with the SEC and Canadian provincial securities regulatory authorities for a discussion of some of the factors underlying forward-looking statements.
We disclaim any intention or obligation to update or revise any forward-looking statements whether as a result of new information, future events or otherwise, except to the extent required by applicable laws.
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About Barrick
•Gold Industry Leader
•20,000+ Employees
•27 Operating Mines
•One of Canada’s Largest Companies
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What we do…
Rock Moving Rock Processing
Our core “Value Stream”
Rock Breaking
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Background: Change needed?
“It is not necessary to change. Survival is not mandatory.”
Dr. Deming
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Barrick’s opportunity (need) for change!
2002 State:• Low gold prices• Tight margins• Rising costs• Poor equipment effectiveness (OEE)
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Background: Benchmarked The Best
Two common themes:
1. Formal CI System
2. CI Culture
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Dimensions of CI at Barrick
FOCUS ONVALUE
CREATION
CULTURE OFCONTINUOUSIMPROVEMENT
“Get results, change the culture along the way”
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Barrick’s CI Launch - 2002
• Top down support • Operations focused• Quick, high impact improvement at Goldstrike property• Expanded to all 9 sites (now 27)
“Get results, change the culture along the way”
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Barrick Vision and Values
To be the world’s best gold company by finding, acquiring, developing and producing quality reserves in
a safe, profitable and socially responsible manner.
BEHAVE LIKE AN OWNERACT WITH A SENSE OF URGENCYBE A TEAM PLAYERCONTINUOUSLY IMPROVEDELIVER RESULTS
Vision:
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Barrick CI Vision
““Everyone Engaged in Improvement Every DayEveryone Engaged in Improvement Every Day””
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Barrick CI – Critical Success Factors
1. Leadership2. Focus on Process3. Measurement4. People & Teamwork5. Communication and Visibility
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Barrick CI – Critical Success Factors
1. Leadership• Sustained Commitment from the Senior Leadership• Highly focused on long-term benefits• Included in Personal Performance Commitments• Full-time dedicated global CI Team of Certified Coaches
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Org. Effect. Ex VP
CI Director
Learning Org. Mgr
Process & Systems
Mgr
CI Coach
RegionalPresident
CI Mgr
MineGM
CI Leader
ProcessingSupt
MaintenanceSupt
MiningSupt
AdminSupt
OperationsDirector
ProcessingCI Coach
MaintenanceCI Coach
MiningCI Coach
AdminCI Coach
Corporate
Region
Site
Barrick CI Organizational Model
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Barrick CI – Critical Success Factors
2. Focus on Process:• Extensive use of all applicable lean tools• Operations Review Teams (ORT’s) embedded in business cycle
(PDR or PDCA)
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JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Talent Review
ORT / Site gap analysis
Strategic Planning
Budget
Performance Commitments
Tactical Plan
Execution
PLAN
PLAN
PLAN
PLAN
REVIEW
REVIEW
Barrick Business Management Cycle
DO
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ORTs – A Key Business Process
1.Review(Assessment)
Objectives
• Current state• Opportunity
Identification
2. Plan(Site Visit)
Objectives
• Leadership support and commitment
• Design solutions
“Go to Gemba”
3. Do(Execute)
Objectives
• Develop & execute action plans
• Monthly Follow-up
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Barrick CI – Critical Success Factors
3. Measurement• Focus on Metrics and KPI’s • Track the value creation (waste reduction)• The Culture Scorecard – yes, you can measure culture
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Barrick CI Value Creation
2003 2004 2005 2006 2007
Valu
e C
reat
ion
Quality Cost Throughput Total
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Key improvements. . .
• Automated feed splitting
• Modified surge pocket/feed chutes
• Surge Pocket Increased
Crusher Throughput - Avg Tons/day
2001 2002 2003 2004 2005 2006 2007
21%
18% 2%2%
26,500
32,150
38,048 38,692 39,544 42,288 43,692
7%3%
65% Improvement!!!
Present: Value Creation Examples
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Present: Value Creation Examples
Before: After:
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Barrick Culture Scorecard
Elements Current Score
12 month Target Key Themes To Close Gaps
Vision & Values 1.8 2.5Business Strategy and Value Streams 2.0 2.3Standardized Processes 0.7 2.3Culture of CI 2.0 2.0Foundation Total 1.6 2.3Recruited for Fit 1.7 2.3Employee Performance and Development 1.4 2.4Talent Management 1.8 2.3People and Leadership Total 1.6 2.3Clear Targets and Goals 1.3 2.0Visual Workplace 1.0 2.0Regular Structured Reviews (Plan-Do-Review) 2.0 2.5Workplace Organization (5S) 1.0 3.0Organization Structured for Performance 1.3 2.0Business Performance Management Total 1.2 2.5Employee Involvement and Problem Solving 1.4 2.3Knowledge Sharing 1.0 2.0CI Resources/Support 1.0 3.0Learning & Knowledge Sharing Total 1.3 2.4Corporate Social Responsibility 0.8 1.8Sustainable Community Development 0.3 1.0Suppliers, Vendors, Contractors & Consultants 1.3 2.3External Relationship Management Total 0.8 1.7
Overall Score 1.3 2.2
Business Performance Management
Learning & Knowledge Sharing
External Relationship Management
Sections
Foundation
People & Leadership
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Lear
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Lear
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Exte
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VISION & VALUES
Business Strategy & Value Streams
Standardized Processes and CI Culture
THE BEST GOLD COMPANY
THE BEST GOLD COMPANY
Lear
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d K
now
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har
ing
Lear
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Bu
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Per
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M
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Per
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Le
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Exte
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Exte
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Rel
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ip
Man
agem
ent
VISION & VALUES
Business Strategy & Value Streams
Standardized Processes and CI Culture
THE BEST GOLD COMPANY
THE BEST GOLD COMPANY
THE BEST GOLD COMPANY
THE BEST GOLD COMPANY
Barrick Cultural Measurement Framework
Major gaps in basic planning and operating standards (CHAOS)
TimeStrong leaders making big, often tough, changes (PUSH)
Focused initiatives in structured process to deliver high impact (DEPENDENT)
Enterprise-wide CI culture (INDEPENDENT)
Results
S0
S1
S2
S3
Not happening
Getting started, limited results
Strong results in critical areas
Everyone Engaged In CI
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Barrick CI – Culture vs. Value Creation?
Higher the Culture Score = Greater the Value Creation
Value Creation and Culture
1.9
1.5
1.11.0
Region A Region B Region C Region D-
0.5
1.0
1.5
2.0
2.5
3.0
Cul
ture
Sco
re
Target Actual Culture score
Valu
e C
reat
ion
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Barrick CI – Critical Success Factors
4. People & Teamwork• Employee Engagement & Involvement• Employees given accountability for results• Willingness to take chances & challenge the status quo• “CI Awards” - Recognition and Reward
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Barrick CI Awards
Recognize and reward employees for improvements made during the year in the following 3 categories:1. Employee involvement and participation2. Idea generation / innovation3. Achievement of significant results
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Barrick CI – Critical Success Factors
5. Communication and Visibility• Create formal systems • Establish Best Practices• Share success
(it’s contagious!)Continuous Improvement
Pocket Guide
First Edition
Continuous Improvement Pocket Guide
First Edition
Continuous Improvement Pocket Guide
First Edition
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Results: supporting ‘real’ value creation
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Our Current Business Environment
• Volatile economic forces
• Fluctuating Gold Prices (+/- 25% in 1 month)
• Inflationary cost pressures
• Labour & commodity shortages
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Summary
– 2 Dimensions• Value Creation• Culture
– Critical Success Factors• Leadership Commitment • Focus on Process• Measurement• Communication and Visibility• People and Teamwork
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Questions
Thank You
Dave Elliott – [email protected] Krawchyk – [email protected]
Please return your completed session survey to the room host.
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