Mill Operations Digital Transformation
Modernizing Equipment Inspections and Shift Communication at Freeport-McMoRan
Overview
This digital initiative replaced manual, paper-based mill operations forms with a user-centered platform that enables real-time equipment inspection data entry and production tracking. Designed for frontline operators and supervisors, the solution enhances communication, decision-making, and operational efficiency.
Challenge
Mill operators relied on paper forms for inspections and production tracking, leading to delays in communication, limited visibility into production issues, and inefficient shift handoffs. Leadership lacked access to timely data needed to optimize performance and ensure operational continuity across teams.
Approach
We conducted immersive field research including user interviews, value stream mapping, and current state analysis to uncover friction points in daily workflows. Insights from frontline operators and supervisors guided the design of an intuitive platform that supports real-time data entry, production tracking, and shift handover. Two MVPs were deployed—Digital Concentrator at Metcalf and Crushed Leach at Morenci—each co-designed with stakeholders to ensure adoption and impact.
Outcome
Frontline adoption reached over 90%, significantly improving shift communication and reducing data entry time. Leadership gained immediate visibility into production metrics, allowing for faster, more informed decisions. The new platform unified mill operations data, reduced reliance on manual processes, and laid the foundation for scalable digital operations across Freeport-McMoRan sites.