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Increasing productivity in processing and smelting plants with advanced analytics

Processing plants are complex, with intricate, non-linear interactions across thousands of variables and multiple trade-offs to solve for. Operating decisions are typically made based on an individual operator’s experience and can vary significantly. Amidst this complexity, technology generates enormous amounts of data across the value chain. When used to its full potential, data can drive productivity improvement and help plants achieve optimal results.
Capturing value from advanced analytics requires multiple skillsets, such as data science, process control and metallurgy, IT, change management, and capability building. OptimusAI leverages a full portfolio of digital solutions that combines science, data, and experts to help mining and processing companies make data-driven decisions to improve productivity, throughput, and recovery.


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Our approach

Our tried and tested approach to advanced analytics brings together a robust delivery process with a collaborative team of specialists—both supported by proprietary technology and products.


We bring a mix of data science, process control, operations, and design expertise, with hands-on experience in applying advanced analytics to improve processing.


With our focus on processing, we have developed a standard recipe for deploying high-impact solutions efficiently and sustainably. We help organizations move quickly to capture impact while building capabilities for long-term success.


Our proprietary capability develops control room advisor systems to improve processing performance. OptimusAI uses state-of-the-art data science to optimize performance in the context of thousands of variables, and includes an easy-to-use interface to process recommendations.

Featured insights

How artificial intelligence can improve resilience in mineral processing during uncertain times

– Even before the COVID-19 pandemic, mineral-processing companies were grappling with profound uncertainty. Those that took steps to harness the power of AI improved agility and operational resilience.

Mining companies’ response to coronavirus

– Mining companies enduring the first wave of COVID-19 effects on their operating models need to think about responding across five horizons.

Accelerating analytics to navigate COVID-19 and the next normal

– Organizations are standing up analytics capabilities in a matter of weeks to inform business responses to COVID-19 challenges and prepare for the future. Here’s how.

How to build AI with (and for) everyone in your organization

– Becoming an AI-driven business requires contributions from your entire workforce. While the transformation takes time, several tactics can begin democratizing AI now.

Has global mining productivity reversed course?

– New analysis of the Mining Productivity Index shows a gradual increase in mining productivity since 2013.

Inside a mining company’s AI transformation

– How copper-mining giant Freeport-McMoRan unlocked next-level performance with help from McKinsey data scientists and agile coaches.

How top companies excel with digital and analytics

– Six key areas to help senior executives manage a tech-enabled transformation.

Global AI Survey: AI proves its worth, but few scale impact

– Most companies report measurable benefits from AI where it has been deployed; however, much work remains to scale impact, manage risks, and retrain the workforce. A group of high performers shows the way.

Catch them if you can: How leaders in data and analytics have pulled ahead

– As data and analytics transform industries at an ever-quicker pace, the strategies and organizational cultures of leading companies offer others a road map for success.

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