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Representative illustration: A global rolled-aluminum producer had under 100 days to prepare a $400M mill upgrade for installation during its maintenance shutdown.

Case Study · Mining & Metals

A global rolled-aluminum producer had under 100 days to prepare a $400M mill upgrade for installation during its maintenance shutdown.

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1Challenge

Entering the automotive market required new finishing, automation and lifting equipment. Many vendors, contractors and sub-contractors had to share space, safety and utility takeover points, and the plant was not ready.

2Approach

  • Built an integrated, critical-path master schedule from precedence networks developed in whiteboard sessions
  • Deployed oversight teams by installation area to prove readiness with checklists and action items
  • Monitored execution shift by shift with custom reports and large-format network plots

3Results

$400M

Mill upgrade program

<100

Days to outage start at engagement

On / ahead

Of schedule where the method was used

Where USC's outage methodology was adopted, work finished on or ahead of schedule.

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© USC Consulting Group 2026 | Mining & Metals. Representative industry image. Results are engagement-specific; sizing and forecast figures are labeled as such.