External VP Operations · Mining & metals

AlexanderShein

I help mining and process-plant owners get new assets to nameplate, and keep existing ones there, as an external VP Operations on retainer.

Operational improvement since 2005: McKinsey, Partners in Performance, operations leadership at Nordgold (acting COO, 9 assets, 9,000 people), EuroChem and EVRAZ. In 2026, led a 4-month project at Ma'aden, Saudi Arabia, with a consulting team.

First measurable result in 4–8 weeks. No 20-person team, no permanent hire.

Alexander Shein

Worked with

  • Ma'aden
  • EVRAZ
  • McKinsey & Company
  • EuroChem
  • SUEK
  • Partners in Performance
  • Nordgold
  • RUSAL
  • LG Electronics

01 · Projects

40+ projects since 2005: ramp-up, maintenance, cost and productivity in mining and heavy industry


Operational readiness and ramp-up of new assets
Operational readiness for a new gold mine under construction
  • Readiness plan that brought start-up and ramp-up to design capacity forward by 4 months, through:
  • 1️⃣ Precise mobilization of resources
  • 2️⃣ Early involvement of operations in acceptance and construction
  • 3️⃣ Continuous short-interval control of the project's critical path
  • Service-level agreements between construction and operations. Requirements reconciled across HR, finance, procurement, construction and the project office. All functions synchronized through a single system of meetings and reporting
Accelerating construction of an apatite fertilizer production unit
  • Diagnostic of construction status; network schedule and critical path of the project
  • Project office set up: structure, functions and responsibilities
  • Risk register and mitigation plan
  • Result: commissioning date brought forward by 4.5 months
Reducing capital cost of a new assembly plant
  • Detailed equipment list built from the capital packages that make up the cost of the whole plant
  • Project requirements matched against what the market can supply
  • Equipment types and alternatives prioritized, critical equipment identified
  • Alternative capital-package list built with new value
  • Result: total capital expenditure for the plant down 19%, about $29 million saved
Production cost, equipment availability and maintenance
Cost-effective availability target and matching purchasing and operating strategy for mining equipment
  • CAPEX down $4.5 million a year at three sites; cost of production down 2.5% through maintenance optimization
  • Analysed the cost of each additional percentage point of availability for mining equipment
  • Justified an acceptable level of total cost of ownership; built the TCO model for the fleet
Operational excellence: reducing losses at a gold processing plant
  • Six Sigma analysis of the measurement system; sources of losses found and reduction projects tracked
  • Mill recovery up 6 percentage points (from 68% to 74%). Direct monetary result about $6 million
  • Variability of extraction parameters analysed, tools built to reduce it, statistically significant causes eliminated
Reducing the cost of iron ore concentrate
  • Cost of the ore beneficiation division down $1.8 per tonne
  • Team of 11. A series of workshops with about 40 people from the process stage to generate ideas
  • 180-190 ideas generated, about 12 launched into implementation during the project. The full pool of ideas allows savings of more than $2.5 per tonne
  • Total annualized result: more than 700 thousand euros a year
Reducing the cost of uranium ore mining and processing
  • Comprehensive diagnostic of every factor driving the cost of uranium mining and processing: operations, commercial and pricing levers, and higher volumes as a way to dilute fixed costs
  • Cost-reduction potential of 15% identified; initiative pool formed, part of it already launched
  • Next steps defined: digitalization of the enterprise and an operational improvement function to secure efficiency and sustainable development
De-bottlenecking and throughput
Lower production cost through higher bottleneck productivity
  • Bottleneck productivity up more than 15%, with a direct impact on profit (operating cash flow up more than $45 million a year)
  • Bottleneck model built, analyses showing the causes of lost productivity
  • Series of idea-generation workshops produced more than 45 initiatives to reduce productivity losses
  • New performance targets built into the business plan
  • Role: project sponsor (16 people reporting, 4.5-month project)
Higher productivity in a drying shop through idea generation and implementation (TOP: total operation performance)
  • Drying shop productivity up 20-25%: part from de-bottlenecking, part from idling unnecessary equipment. Total effect about $6-8 million a year
  • About 90 plant specialists trained and interviewed using the TOP methodology
  • Pool of 80 initiatives; about 50 of them delivered results within the first two months of the project
  • Role: head of department (4 people)
Higher productivity of a ferrochrome plant
  • Smelting furnace productivity up 15% in 3.5 months
  • Basic digital assistant proposed and implemented as a prototype of a full-scale neural network that prompts operators on smelting modes
  • Short-interval control of process modes and charge feeding introduced, stabilizing the process
  • Sludge processing shop optimized separately, raising recovery by 4 percentage points
Operating models, organization and incentives
Target operating model for a company with 40,000+ employees
  • Functional verticals defined: maintenance, technical, operations
  • KPIs set for each vertical
  • Main cross-functional processes designed and implemented
  • Organizational structures, processes and KPIs aligned
  • Procedures and tools that track the sustainability of the transformation
Organizational practices in the energy sector
  • Organizational structure optimized; root-cause analysis practices introduced; KPI system and incentives implemented
  • Structure revised for companies with 600-1,000 employees
  • Skills requirements and staff grades developed
  • Total headcount down 14%
  • Incentive system revised around the production KPI structure
Fewer management levels and a new incentive system in gold mining
  • Project leadership: 3 plant directors reporting (about 900 people)
  • Labor productivity up 22% in 1.5 years. One management level removed. Higher employee engagement
Digital tools and AI in operations
Development and implementation of OptimusAI, a digital optimization tool for a metallurgical plant
  • Development and adaptation of the solution
  • Assessment of the implementation potential; target levels for operational metrics after deployment
  • Expert support to the team
  • Making sure the tool is used: training, audits
Network of expertise centers in assembly manufacturing
  • A structure that regularly gathers new technologies from outside the company and generates new ideas
  • More than 60 people in two reporting levels
Underground mine planning system
  • Compliance with mine plans up from 48-50% to 84-88%. The change is sustained without consultants on site
  • Underground mine planning model developed and deployed at two of the company's sites
  • Role: project manager (10 people)
Digital roadmap for a mining and processing enterprise
  • Current digital solutions and infrastructure analysed; landscape of potential digital solutions and selection criteria for use cases that fit the enterprise
  • Skills of IT and related functions assessed
  • Result: digitalization roadmap, with the potential of digital projects and their impact on the enterprise NPV assessed
  • Target vision for the enterprise, with implementation plan and resource requirements
Digital solutions for a mining enterprise
  • AI-based digital expert for haul truck repairs: helps service specialists identify the cause of a failure and suggests how to fix it
  • AI digital advisor for optimal control of the flotation process
  • Set of optimization models for mine-to-mill processes, setting optimal modes for several process stages
  • Neural network for product quality analysis: detects contaminating inclusions in the ore flow from a video stream
Product quality
Product quality at a petrochemical plant
  • Main quality indicator reached Cpk = 1.0 (project target) and held there for three months
  • Product quality stabilized; new markets won
  • Total project effect: more than $15 million a year
Stabilizing the quality of assembly-line products to cut cost
  • Voice of the customer: customer requirements analysed, standardized and unified, then converted into production requirements
  • Production requirements split into requirements for each site. Control charts set up, variability reduced, process rearranged to meet the new product requirements
  • Result: production cost down 11% through unified specifications and fewer losses from over-specified quality. Annualized effect more than $16 million a year
Lean systems and capability building
Lean training program for one of Russia's largest banks
  • Series of trainings for bank employees; training programs evaluated and refined
  • 130 people trained. 20-25 internal trainers established who teach bank employees the new tools
Staff skills development program
  • Lean Academy set up. 60 employees trained, including supervisors (petrochemicals)
  • Skills assessment system developed and handed over to HR
Lean in power generation
  • Maintenance optimization, more effective equipment inspection rounds, a practice of generating small technical improvement ideas
  • System for planning, diagnosing, adjusting and monitoring repair plans introduced (based on MS Project)
  • 6 repair standards and 4 inspection-round standards created for one of the boiler and turbine shops
  • Process for generating, assessing and implementing improvement ideas at the plant
  • KPIs by area built into the incentive structure of the responsible managers
Lean in a bank (top-20 banks in Russia)
  • 5 lean workstreams implemented in one of the bank's divisions
  • Lean management practices implemented
  • 5S procedures established
  • Flexible staffing model: employees move to desks as clients arrive
  • Money transfer and online banking processes simplified; visual boards and a performance management meeting system introduced
  • Lending processes for small and medium-sized enterprises optimized
Lean in the woodworking industry
  • Pressing area productivity up 6%. Work standards for the 4 most critical operations implemented
  • Plant meeting and reporting system redesigned; standard daily schedule for foremen and supervisors introduced
  • Employee engagement and its drivers assessed
Strategy, markets and product portfolio
Global copper production and consumption strategy for global corporationsProduct line development in plywood production
  • Margin of each product estimated
  • Sales and production synchronized. Priority system created to maximize production load and overall efficiency
  • Product priority system developed
  • More than 20 idea-generation sessions and interviews held to understand market potential
AI tools for marketing strategies
  • Automated AI chatbot built to sell the products of several companies
  • More than 40 SMM specialists and marketers trained to work with neural networks
  • CRM integration built to analyse call-center call quality using OpenAI Whisper
Promoting a drug in the bronchial asthma market
  • Value stories created and staff trained
  • Three value stories; 12 employees trained
  • Sales channels developed; risks and benefits of each channel assessed
  • Several promotion scenarios for the year ahead

02 · Experience

Operations leader and consultant since 2005: McKinsey, Partners in Performance, Nordgold, EuroChem, EVRAZ


Independent Expert - operational transformation, with international consulting firms (May 2026 – present)
  • Expert and workstream-lead roles on operational-transformation and performance-improvement engagements in Saudi Arabia, Jordan, Kazakhstan and Uzbekistan, on site and remote
  • 2026: led a four-month project at Ma'aden (Saudi Arabia) as part of a consulting firm's team
  • Saudi Arabia: on-site expert on a large infrastructure program — operating model, performance management and delivery governance
  • Jordan, Kazakhstan, Uzbekistan: operations diagnostics, process management and operating-model design for industrial and public-sector clients
  • CEO advisory for mid-market owners through Practica 101, with a proprietary diagnostic toolkit: loss map, measurement map, maturity model, KPI cascade
EVRAZ - Head of Target Operating Model Program, CEO-1 (June 2025 – May 2026)
  • Led the holding-wide operating-model transformation: 40,000+ employees, 6 assets, 3 geographies; reported to the CEO, worked daily with VPs
  • Designed three functional management contours with re-allocated roles, decision rights and accountabilities
  • Defined the catalog of key processes, surfaced control and transparency risks, set target KPIs per process owner
  • Launched focused improvement projects (maintenance, HSE, logistics) with roadmaps and measurable impact targets
  • Built and led a transformation office of 18+ people
Independent Expert - affiliated with several consulting firms (January – June 2025)
  • Originated and sold projects in mining and operational improvement; coached project teams and client leaders
  • Developed a methodology and toolkit for operational transformations
  • New offerings: China sourcing strategy, digital transformation under sanctions, AI implementation in industry
McKinsey & Company - Engagement Manager, Global Energy & Materials, Almaty (August 2023 – December 2024)
  • Led business development in mining across Kazakhstan and neighboring countries
  • Coordinated the practice's CxO materials on digital and generative AI for mining and metals, used in pitches across Kazakhstan, Uzbekistan, Azerbaijan and Türkiye
  • Underground ferrochrome mining: +25% daily productivity
  • Ferroalloy plant: +15% smelting productivity in 3.5 months
  • Iron-ore mining and processing complex diagnostic: 22% upside identified
  • Led the group that collected global trends in copper production and consumption in 2024 for the firm and its clients
Practica 101 - Managing Director, own operational-consulting firm (November 2022 – June 2023)
  • Ran the firm (10 people); delivered 4 full-cycle projects across heavy industry and CEO advisory for mid-market executives
  • Ship-repair company: turnaround time cut by more than 20%
  • Coal-mine diagnostic: +11% productivity potential from digitalization
  • Electronic shift-order system rolled out at a gold mine
EuroChem - Head of EuroChem Business System, mining division (April 2020 – October 2022)

Led 4 navigator teams across 4 sites

2020 impact: about $30 million (300,000 metric tons of KCl)

Key initiatives:

  • De-bottlenecking (mine and plant): fewer unplanned and planned repairs, higher productivity of the beneficiation sections
  • Cost reduction: cost dialogues, budgets delegated to shop-floor managers, controls in place
  • Management infrastructure: structured reporting and meetings, visual management centers, incentive system aligned with employee KPIs

Culture transformation: engagement program, idea factory, training program

SUEK - Acting Head of Operations Improvement, interim, in parallel with EuroChem (August – December 2020)
  • Set up 3 teams on 2 pilot projects to accelerate development at Kuzbass coal mines
  • Development rate +15–22% at both mines within the first 4 weeks
  • Maintenance program for 41,900 equipment units (RUB 15.4B budget) approved by the Strategic Committee
  • Extended the EuroChem business-system toolkit to SUEK projects
Partners in Performance - Associate Principal, management consulting (September 2017 – April 2020)
  • Performance-improvement projects in mining, metallurgy and energy
  • Gold mining, Ghana: +56% productivity
  • Nickel producer: IT-based underground planning across 3 mines; plan adherence 50% → 88%
  • Coal mining: faster development; trained a local team of 8
  • Phosphate fertilizers: higher recovery and equipment productivity
Nordgold - Deputy COO, CEO-2; acting COO of the whole company for 8 months (June 2012 – May 2017)
  • Managed 4 assets in Russia, Kazakhstan, Guinea and Burkina Faso, with their CEOs reporting to me. Accountable for business-plan delivery: financial, safety, production and capital-project targets
  • Within two years of start-up every asset generated stable cash flow (+$2 million to +$54 million each) and sat in the first cost quartile of the industry benchmark, about $98/oz below the industry average
  • Built stable site management teams (turnover under 7% a year on a fly-in, fly-out basis); labor productivity up 22% through a new incentive system and a flattened three-tier management structure
  • The cost-reduction program (Total Production Optimization, lean, Six Sigma) was taken up by the workforce and funded a new plant without external investment, as well as extending the life of existing plants
  • Acted as COO of the entire company for 8 months: 9 assets and 9,000 employees
  • Mining fleet and plant availability sustained at 85-87% through the maintenance and repair system built across the sites
  • Sponsored cross-functional projects across my region: a cost-effective maintenance and repair system, SAP implementation
  • Operational readiness and assurance for a new mine: built and ran the readiness tracking plan, adapting methodology from construction and petrochemicals
  • Closed one of the group's businesses, settling claims of tax and regulatory bodies, and kept the best people inside the group through a high-potential assessment and transfer program

Also led the analytics and production-reporting unit (3 people): meeting cadence, production reporting, integration of SAP and MES data into routine management reporting

McKinsey & Company - Analyst → Operations Specialist → Project Manager, Operations practice (November 2008 – June 2012)

Started as a production analyst focused on operational efficiency and went through 8 projects (2 as analyst, 5 as specialist, 1 as manager), including:

  • Iron ore: cost-reduction program (TOP methodology). Led a team of 8. More than 20% cost reduction at the site
  • Power generation: lean implementation. Designed and implemented a planned-maintenance system that cut repair costs by 20% and improved equipment reliability (18% fewer unplanned failures in 5 months). Six Sigma elements used to sustain the change
  • Petrochemicals: product quality improved through a Six Sigma project; process stability improved by about 16% (Cpk). Technical changes were backed by organizational ones, including a new incentive system prioritizing quality indicators
  • Banking: two lean implementation projects. More than 150 employees trained as change agents. On one project built a model 'lean laboratory' with best practices (led 6 people). The branch ran at 30% lower cost; headcount fell as 12-15% of customers moved to remote channels
  • Plywood manufacturing: lean implementation focused on mindsets and behavior. Interviews, mapping the values of different employee groups and tools to sustain the change

Within the European Operations practice, developed two knowledge-building projects; one resulted in a training installation at the firm's Frankfurt capability center to teach clients new ways of working

RUSAL - Project Manager, repair optimization with Lean tools (May 2006 – November 2008)
  • Joined a project run with foreign consultants to raise equipment reliability. Result with a small kaizen group (2 workers): mean time between repairs doubled (about 211%) with repair time down more than 12%
  • Promoted to project manager (June 2007): drove the change in maintenance using lean methodology. Led 4 groups at 4 plants (14 people). Focus areas: cost reduction, identification of critical defects, technical and organizational solutions to eliminate root causes of failures
LG Electronics (Changwon, South Korea) - head of production area, design engineer for new refrigerator models

Joined as an engineer on a project to develop a refrigerator for the Russian market, with development done at the plant in South Korea. Designed the mechanical joints of the unit (the model sold in Russia in 2007-2010). At the same time trained more than 90 assembly-line workers in Korean quality assurance systems. After the project, focused on lean production systems and the organization of the future plant

Back in Russia (February 2006), set up the R&D department and trained staff in the LG manufacturing system

03 · Education and publications

Education, publications and speaking


Education and skills
  • 2023: McKinsey Team Leader Orientation Course
  • 2024: Knowledge update (McKinsey training) on technology-enabled operational excellence and the use of AI in large businesses
  • 2016: Australian Institute of Company Directors, Company Directors Course
  • 2015: Darden School of Business, Executive Program: Strategic Leadership at the Top
  • 2009-2011: Economics degree (First Economic School, Moscow)
  • 2008: Training in running operations projects (McKinsey)
  • 2006: Training in production optimization tools (McKinsey)
  • 2006: Six Sigma Black Belt (LG Innovation School, Changwon, Korea)
  • 1998-2004: M.Sc. in Mechanical Engineering (Bauman Moscow State Technical University, Russia)
Publications and speaking

04 · Contact

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