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Welcome to EGCA Consulting

Expert Global Consulting Agency

Unlock potential by breaking down challenges into actionable solutions. EGCA’s expertise ensures clarity and high ROI at every step.

About Us

EGCA is a consulting firm dedicated to operational excellence. We specialize in providing tangible benefits to our clients, emphasizing efficiency and enhancing the bottom line. Our approach is pragmatic and results-driven, avoiding superficial solutions. We excel in solving complex problems and assisting the mining industry through the implementation of digital twins.

In Proud Collaboration With:

XMPro is a No Code Digital Twin Composition Platform that accelerates Operational and Situational Awareness.

Clients In All Major Heavy Industries

Our Team Has Experience Working Across A Wide Range of Industries

Mining
Processing
Oil & Gas
Construction
Logistics
Manufacturing

Trusted By Industry Leaders

Our Services

Our Consulting Offering Is Output Focused

Throughput Improvement
Modelling performance, identifying drivers of underperformance & developing solutions to close gaps.
Cost Reduction
Modelling spend against budget and target, identifying primary drivers of overspend and implementing initiatives to manage spend
Capital Project Optimization
Optimise and manage capital project’s NPV, Readiness, Reporting, Critical Path Reduction, Rate of Work and Quality
Management Operating System & Strategy

Design and Evaluate MOS to maximise visibility and drive accountability (meetings, KPIs, reports etc.)

Supply Chain Optimisation

Procurement and Sourcing, Warehouse Optimisation and Logistics efficiency and planning.

Digitalisation
Digital roadmapping, predictive and prescriptive analytics roadmapping and implementation, autonomous haulage etc.
Engineering & Maintenance

Support along the full maintenance life-cycle. Minimise unplanned downtime and optimise artisan utilisation

Energy Efficiency / Transitioning

Introducing global best practices in energy efficiency and alternative energy to ensure the security of our supply.

Our Services

Our Consulting Offering Is Output Focused
Throughput Improvement
Modelling performance, identifying drivers of underperformance & developing solutions to close gaps.
Cost Reduction
Modelling spend against budget and target, identifying primary drivers of overspend and implementing initiatives to manage spend
Capital Project Optimization
Optimise and manage capital project’s NPV, Readiness, Reporting, Critical Path Reduction, Rate of Work and Quality
Management Operating System & Strategy

Design and Evaluate MOS to maximise visibility and drive accountability (meetings, KPIs, reports etc.)

Supply Chain Optimisation

Procurement and Sourcing, Warehouse Optimisation and Logistics efficiency and planning.

Digitalisation
Digital roadmapping, predictive and prescriptive analytics roadmapping and implementation, autonomous haulage etc.
Engineering & Maintenance

Support along the full maintenance life-cycle. Minimise unplanned downtime and optimise artisan utilisation

Energy Efficiency / Transitioning

Introducing global best practices in energy efficiency and alternative energy to ensure the security of our supply.

Our approach is aimed at clarifying our ROI

Diagnostic

Answers 4 simple questions

  • What is the problem?
  • What’s driving the problem?
  • How do we fix it?
  • Who and when?

What you get:
Alignment on the problem backed by analytics and prioritized solutions mapped out.

Implement

Putting paper into action by setting up accountability mechanisms.

  • KPIs, owners, and meetings
  • Workplans and reports

What you get:

Infrastructure to ensure continuous improvement and ongoing generation of ideas.

Sustainabilty

Empowering your organization to “not need us.”

  • SOPs built into the organization
  • Elimination of silos

What you get:

Documentation, training, and confidence to manage continuous improvement independently.

We Have Proven Results

Successfully supported production ramp-up to achieve 230kt/month by improving performance on all drivers of daily blast performance sustainably.

Successfully reduced AISC by ~$170/OZ through higher confidence initiatives and ~$375/OZ to achieve Full Potential of below $1000/OZ, targeting an overall cost reduction of ~$100m.

Identified and implemented improvements resulting in an increase of NPV by R20.5bn through the rapid optimization of capital expenditure, reducing capex, operating cost per ton, and changing base project assumptions.

Successfully improved NPV by R200m – R250m through fast tracking the schedule and increasing the overall development rate, reducing cost, schedule, and revenue on an underground manganese mining project.

Successfully managed large scale capital projects such as the Gautrain extension and Kinsevere Copper mine Phase II extension by preparing financial projections, managing project budgets, and conducting cost benefit analyses.

Designed and rolled-out reporting and MOS tools in 4 weeks across all levels of the organization that drove a 19% improvement in tonnes sent out on rail and 12% reduction in the time it took to load trains.

Built a Power BI report for the mine MD that tracked progress and delays on critical projects for the mine’s 12-month ramp-up

Developed and implemented initiatives to drive more efficient offshore logistics planning and warehouse operations. Built a live model to track material movement and location offshore to prevent loss.

Developed complete Life-Of-Mine model for both mines to identify revenue boosting and cost reduction initiatives to make both mines profitable and improve IRR from 19% to 27%

Supported a South African Iron Ore mine with a roadmap to make moving to a fully autonomous (driverless) trucking fleet profitable

Full business transformation across production and engineering with fully set-up and tracked initiatives in Power BI including shift structure changes, spares readiness, MTTR reduction with satelite workshops etc.

Developed several trackers, patient journey and stock journey that gave the management team and ground staff clarity over the Operational Readiness status and assisted with ramp-up speed and management.

Created a consolidated tracker that tracked inventory levels, warned of shortages and allowed for sharing between the labs when oversupply occurred

Spent 2-5 weeks identifying the biggest value opportunities in the business and develops a complete roadmap to achieving these (more broad when problem unclear)

Developed and implemented various pricing strategies at a global quickcommerce company that sold over 12 000 SKUs to optimise margin and manage demand and stock levels.

Successfully completed feasibility studies, implemented quality control, and managed turnkey projects during a ten-year career at Stefanutti Stocks Civils.

Facilitated implementation of cost reduction initiatives valued at over R30m as part of an overall cost reduction worth over R300m and integrated Partners in Performances’ PIPware software platform with the client’s data system.

Designed a rightsized organisation to match revised mine plans for two operations and identified other optimization opportunities to together reduce mining costs by 12.21%.

Successfully reduced commercial sourcing costs by R174m, significantly improving profitability on a Platinum Mine.

Let us do the same for you

Contact Us

To get in touch, please enter your message into the form below or send an email to info@egca.io.

Our Offices
South Africa

First Floor, Building 8

 

Kildrummy Office Park

 

Umhlanga Avenue

 

Tel: +27 65 083 1397

Barcelona

Consell de Cent

 

Barcelona, Spain

 

Tel: +34 627 03 75 15

Democratic Republic of Congo

Kolwezi le Lubumbashi Lido

 

Tel: +243 81 932 3941

Empowering Operations, Together.

Simplicity | Rapidity | Sustainability

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