The Witness model simulates the whole logistics and production value chain
This simulation model integrated logistics planning with production needs, providing real-time feedback on potential bottlenecks or material shortages before they could disrupt operations. As Dina Tiets described, "Before using the simulation model, we had no real-time overview of concentrate movements. Now, we know exactly when shipments are arriving and can adjust our production plans accordingly."
One of the standout features of the simulation was its ability to force collaboration between previously siloed departments. “Now,” Bryan explained, “planning can go and run their plan, see that there’s a problem, and collaborate with logistics to adjust either the plan or the material delivery schedule.” This capability empowered the teams to make informed decisions before issues arose, fostering a new level of operational synergy.
The input screens used by the users at Tsumeb to set up their scenarios
The benefits of this predictive simulation were immediately measurable. For Sinomine, the time required for weekly production planning meetings dropped from three hours to just 20 minutes. The ability to visualise and adjust plans based on real-time data meant that logistics and production schedules were aligned, reducing costly downtime and ensuring a more stable production flow.
The results of the simulated scenarios provide the Tsumeb team with the necessary details to execute their plans with confidence
One particularly notable outcome was the impact on sulfuric acid production, a byproduct of the smelting process. With the simulation, the smelter could accurately forecast sulfuric acid output and ensure timely delivery to its customers. As Dina explained, "We model shipments and production together, so we know exactly when we can deliver sulfuric acid without exceeding our capacity or causing production to stop."
The Sinomine team have been using the simulation for more than four years now – a testament to the value they feel it provides them. “Our most successful implementations come down to three, equally important, factors – data, modeling, and people” Sean Mowatt explains. “Regardless of the technical sophistication of the solution, if it is not perceived to be easy to use while delivering real-world value, it will not be used sustainably. The inputs and guidance provided to us by the Sinomine team in setting up and enhancing the solution was, and continues to be, crucial to its longevity.”
The collaboration between BSC’s Productivity Science division and Sinomine Tsumeb Smelter highlights the power of predictive simulation in modern logistics and production planning. By integrating data from both departments and providing a unified platform for scenario analysis, BSC’s solution has helped Sinomine reduce costs, avoid production delays, and improve decision-making across the board.
As industries like mining and smelting continue to evolve, tools like the predictive simulation model implemented at Sinomine will play a crucial role in shaping the future of operational efficiency. Whether it’s reducing downtime, minimizing costs, or fostering greater collaboration between teams, the results speak for themselves: smarter planning leads to better outcomes.