United StatesManufacturing2018 – ongoingFreeport-McMoRan
AI recommendations for Bagdad concentrator settings
Freeport-McMoRan increased Bagdad copper production by 5% after operators adopted AI recommendations, McKinsey reported
Problem
Freeport sought more copper production from existing assets because expansion required substantial capital and lengthy permitting. Its Bagdad operation needed higher processing rates without compromising safety.
Approach
A team of metallurgists and plant staff worked with engineers to train a model that recommended mill settings. After testing, operators implemented its recommendations. Plant specialists helped evaluate recommendations and identify model flaws.
Results
Takeaway
Operators participated in testing before they were asked to use the model's recommendations in production.
Categories
- Size
- Large enterprise
- Industry
- Manufacturing
- Business function
- Production and quality
- Innovation type
- Process innovation
- AI technology
- Predictive analytics and MLOptimization
- Adoption
- Built in-house
- Evidence
- Vendor case study
Sources
Source summaries
McKinsey described the Bagdad team's development and operational use of AI recommendations for mill settings. It reported a 5% production increase and a 10% quarter-on-quarter throughput increase, alongside improved copper recovery.
Full details are in the original sources.