- Case Studies
Delivering Fortescue Zero’s Roadrunner, the Battery-Electric Haul Truck Programme
- PMO & Project Delivery
Fortescue Zero is a division of Fortescue Metals Group, a global leader in mining, committed to advancing sustainable practices. The Roadrunner Battery Electric Truck (BET) Programme aims to electrify Fortescue Zero’s 240-tonne mining truck, replacing diesel powertrains with a state of the art battery-electric system.
The power system was developed in Oxfordshire, UK, installed in Perth, Australia, and tested in Pilbara, Western Australia, under extreme environmental conditions. The project required cross-functional collaboration across continents, spanning design, manufacturing, and deployment phases, all while adhering to stringent timelines.
Unlike traditional mining vehicle projects, which typically take 5+ years to complete, the Roadrunner project was delivered in just 22 months. This remarkable achievement reflects a new approach to programme governance, featuring empowered teams, agile decision-making, and robust project controls.
Partnering with MIGSO-PCUBED (MP), Fortescue Zero overcame substantial challenges to deliver this ambitious project. From its inception to final deployment in harsh mining environments, the Roadrunner BET Programme showcases the transformative potential of structured project management, innovative collaboration, and a commitment to sustainability in the mining industry.
The challenge: accelerating innovation amid unprecedented constraints
Fortescue Zero faced numerous challenges in delivering the Roadrunner BET Programme:
Technical Complexity:
- Designing and manufacturing a bespoke electric powertrain system.
- Developing unique CAD data to support the power system design.
Operational and Supply Chain Constraints:
- Scaling up production processes while meeting tight schedules.
- Navigating supply chain disruptions exacerbated by global challenges.
Collaboration Across Borders:
- Coordinating teams in different time zones (UK and Australia) without travel due to COVID-19.
- Ensuring effective communication and seamless collaboration using digital tools.
Governance and Adaptability:
- Traditional project governance models often impede agility and rapid decision-making. Fortescue Zero needed a framework that balanced precision with urgency.
The solution: driving success with structured innovation
MP addressed these challenges with a multi-faceted approach, leveraging advanced project management tools, lean methodologies, and a culture of empowerment.
Structured planning and monitoring
MP developed a comprehensive programme plan featuring clearly defined milestones and key performance indicators (KPIs). A visual scheduling tool tracked progress, enabling rapid adjustments to accommodate changing requirements. Bi-weekly reviews provided a real-time feedback loop, ensuring alignment with business goals and maintaining project momentum.
Advanced risk management
To mitigate risks, MP implemented an in-house PMO tool and JIRA for issue tracking. Regular risk reviews identified potential roadblocks early, while root cause analyses allowed teams to devise proactive solutions.
Lean manufacturing transformation
MP introduced lean manufacturing tools to streamline the operational build process. This innovation reduced the build time from 8 weeks to just 3 days, a game-changing improvement in efficiency.
Visual management for transparency
MP established Obeya rooms (large-scale visual management spaces) to foster transparency and accelerate decision-making. These rooms enabled cross-functional teams to quickly share information and address bottlenecks.
Continuous improvement initiatives
Kaizen workshops encouraged ongoing process refinements. MP facilitated lessons-learned sessions with over 50 participants, identifying 240 unique insights, with 60 priority recommendations incorporated into future programmes.
Agile governance and decision-making
By replacing traditional governance with agile Steering Committees and senior gateway reviews, MP ensured swift and informed decision-making. The introduction of a decision-making matrix streamlined accountability and expedited critical approvals.
Benefits: transforming challenges into measurable success
MP’s structured approach delivered outstanding results:
Time and cost efficiency:
- Delivered the Roadrunner BET from concept to completion in just 22 months, significantly faster than industry norms.
- Reduced build time by 97%, from 8 weeks to 3 days.
Enhanced collaboration:
- Utilised digital collaboration tools to overcome geographical and logistical barriers, ensuring uninterrupted progress.
Operational resilience:
- Successfully deployed and tested the truck in Pilbara, demonstrating its robustness in harsh mining environments.
Knowledge transfer:
- Lessons-learned workshops yielded actionable insights, strengthening Fortescue’s Zeros future decarbonisation efforts.
Sustainability leadership:
- Positioned Fortescue Zero as a trailblazer in sustainable mining, paving the way for future electrification initiatives.
The Roadrunner BET Programme exemplifies the power of innovative project management in delivering transformative outcomes. By combining structured planning, lean methodologies, and a culture of empowerment, MP helped Fortescue Zero achieve an ambitious goal: the successful development and deployment of a battery-electric mining truck in record time.
This achievement not only advances Fortescue Zero’s sustainability objectives but also sets a new standard for decarbonisation in heavy industry.
Thank you Serena Martin and Hussain Ladak for contributing to this article.
Key results
MP helped Fortescue Zero deliver Roadrunner from concept to completion in just 22 months:
- Build time was reduced by 97% (8 weeks to 3 days)
- Lessons learned sessions were held with over 50 participants
- 240 unique insights were identified
- 60 priority recommendations suggested to incorporate into future programmes
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