There, the problem was different. The mill power wasn't erratic—it was stubbornly stable. And that was worse. Because the cyclone overflow particle size (the % passing 75 microns) was drifting downward, slowly but surely. The shift supervisor kept increasing the mill feed rate to compensate, chasing the tonnage target.
She didn't celebrate. She opened her laptop instead. Statistical Methods For Mineral Engineers
The daily average? It had dropped to 1,150 tonnes per hour. But the shift tonnage—the real money—was actually up 5% because the mill never stopped. There, the problem was different
“For the last six hours,” she said, pointing to a string of seven points all below the centerline, “we have been running fine. But this run of seven points all below the mean? That’s a Nelson Rule violation. It’s not out of control statistically, but the probability of this happening by chance is less than 1%. It’s a trend. The mill is grinding finer because the new media supplier’s ball hardness is different. We need to back off the feed rate now—not in two hours.” Because the cyclone overflow particle size (the %
“You’re chasing your tail,” she said. “The crusher power draw spikes, you back off. It drops, you tighten. But the lag in your feedback means you’re always reacting to what happened five minutes ago. By the time you fix it, the feed has already changed. You’re creating the instability you’re trying to solve.”