01 · Reliability Turnaround
From breakdown to benchmark: the Koingnaas diamond plant
A plant that broke more than it ran, turned around in one operating year with visual work management, Pareto focus, FMECA and the courage to take a plant back to basics.
P/R 1.1 → 1.6 in one year · primary stockpile cleared · approach scaled across all operations
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02 · Fleet Reliability
New Vaal: 120,000-hour haul trucks to 90%-plus reliability As told by Steve Möller
The Divisional Engineer behind Koingnaas applied the same principles to a worn Hitachi haul-truck fleet — proving the method is asset-agnostic.
90%+ fleet reliability in 6 months · no fleet replacement · old iron, disciplined system
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03 · Defect Elimination
When “bearing replaced” is not a root cause
A conveyor take-up bearing caught fire and the report closed at “bearing replaced” — within hours. The five-why chain the event deserved, and the strategy that prevents the repeat.
Failure mode ≠ root cause · three root levels · the fix is a strategy, not a spare
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04 · Methodology & Culture
When the analysis stops: the RCFA the boardroom killed
A sound silo-failure investigation that died at the verification step — because leadership expected a silver bullet, not a method. The honest case study most consultancies won’t publish.
Two root causes — one technical, one organisational · the fix happens before the analysis
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