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.
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
- 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
- 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
- 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
- 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
- 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
- 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
- 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
- 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)
- 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)
- 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
- 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 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
- 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 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
- A structure that regularly gathers new technologies from outside the company and generates new ideas
- More than 60 people in two reporting levels
- 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)
- 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
- 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
- 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
- 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
- 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
- Lean Academy set up. 60 employees trained, including supervisors (petrochemicals)
- Skills assessment system developed and handed over to HR
- 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
- 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
- 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
- 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
- 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
- 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
- 2025 - information partner of the Enterprise Modernization '25 conference
- 2024 - speaker at the Leanthusiasts club: "After Lean: new technologies for improving operational efficiency"
- 2024 - moderator at the GoDigital 2024 conference, section "Process robotization and automation", and speaker: "Practical cases of GenAI application in industry"
- 2024 - presentation at the gold miners' forum (Mining and Metallurgical Congress, Kazakhstan): "Global trends in gold mining"
- September 2022 to February 2023 - member of the Academic Council of the Production Systems and Operational Efficiency master's program at the Higher School of Business (Moscow)
- 2022 - Master in Management Analytics, SKOLKOVO MMA. Talk: "Increasing profitability with analytics"
- 2022 - Smart Manufacturing Systems Summit. Talk: "Expert initiatives: an additional source of improvement ideas and their synergy with operational efficiency"
- 2021 - InnoWave Conference. Talk: "Problem-solving techniques in production. New technologies"
- 2017 - Lean Forum (Udmurtia): round-table host, "Peculiarities of implementing incentive systems: why Western copies do not work"
- 2016 - Autumn Forum of construction companies (Moscow, Expocentre): "Methodology for preparing operations for the end of construction"
- 2014 - Lean Forum (Moscow): "Implementing lean manufacturing in low-skill environments"
- 2014 - HR Forum Moscow (RSPP): "Involving expats in Russian companies"
- 2013 - Technical Universities Development Initiative: "Sustainability of operations transformation"
- 2012 - McKinsey functional practices championship (practice Olympics): first place in the Moscow office
04 · Contact
Book a 20-minute call
Pick a 20-minute slot in the calendar, it shows times in your time zone. Email works too: I reply within 24 hours.