Modular Mining https://www.modularmining.com/ MineSmarter Thu, 26 Aug 2021 00:07:57 +0000 en-US hourly 1 https://wordpress.org/?v=6.4.3 https://www.modularmining.com/wp-content/uploads/2019/03/cropped-MMSI-Favicon-512x512-32x32.png Modular Mining https://www.modularmining.com/ 32 32 Modular Mining is part of Komatsu’s new Mining Technology Solutions team https://www.modularmining.com/komatsu-new-mining-technology-solutions-team/ https://www.modularmining.com/komatsu-new-mining-technology-solutions-team/#respond Wed, 25 Aug 2021 23:32:59 +0000 https://www.modularmining.com/?p=13517 On August 18, 2021, as part of advancing its smart mining vision for customers, Komatsu announced via press release the alignment of its mining business segments, including Modular Mining and MineWare. The new Mining Technology Solutions team brings together global expertise from across Komatsu's businesses to focus on rapid technology advancement.

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New Mining Technology Solutions team brings together global expertise

On August 18, 2021, as part of advancing its smart mining vision for customers, Komatsu announced via press release the alignment of its mining business segments, including Modular Mining and MineWare. The new Mining Technology Solutions team brings together global expertise from across Komatsu’s businesses to focus on rapid technology advancement.

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As part of this evolution, the MineWare brand will be discontinued; its Argus and Pegasys solutions will now be included in the Modular Mining brand portfolio. The Modular Mining brand will continue to focus on real-time, OEM-agnostic digital offerings, and all Modular Mining and MineWare employees have been integrated into the new Mining Technology Solutions team.

The team’s current project is developing the new Intellimine Synergy open-technology platform, which will debut at MINExpo International in Las Vegas next month. The platform seeks to align common goals of being more agile and collaborative, increasing efficiencies and leveraging the full capacity of Komatsu’s mining experience.

“The number of data sources available to our customers now can be overwhelming,” said Jeffrey Dawes, President and CEO of Komatsu Mining. “So, we set out to provide a solution that seeks to cut through the noise; to provide a single source of real-time information that can assist, automate and help optimize the important decisions customers make every day.”

“Designed to collect, integrate and process data in real time, Intellimine Synergy is on track to be an industry first for offering customers a single source of actionable insights through an open-technology platform that brings together data from all relevant Komatsu, Modular Mining and third-party machines, mining processes, systems and technology applications.”

To find out more about the new Mining Technology Solutions team, read the press release from Komatsu.

To find out more about how the Komatsu Mining Technology Solutions team is leveraging next-generation optimization algorithms and open-technology solutions, join us in person at MINExpo Sept. 13-15 at the Modular Mining booth, #7671, and the Komatsu booth, #7027.

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Mining Optimization: Achieving the connected mine https://www.modularmining.com/mining-optimization-achieving-the-connected-mine/ https://www.modularmining.com/mining-optimization-achieving-the-connected-mine/#respond Thu, 18 Feb 2021 22:33:54 +0000 https://www.modularmining.com/?p=13090 In this second post of our Mining Optimization series, we'll dig deeper into the benefits of robust optimization across the mining value chain, especially towards the journey of a connected mine. We'll explore each of our five new Modular Mining APIs, and how they can help mining organizations start driving towards mine-wide optimization.

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Mining Optimization Series: Part 2

Achieving the connected mine

The first blog post in our Optimization series focused on the basics of mining optimization: what it is, what it isn’t, and why it’s important. We gave examples of real mines who have seen real improvements as a result of a focus on optimization.

In this post, we’ll take our discussion about optimization a step further, and explore some of the latest mining innovations that are helping organizations get closer to achieving the sought-after “connected mine.” By focusing on optimization, and leveraging the integrated capabilities of multiple technologies, mines everywhere can improve productivity across the mining value chain.

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Integrating Fleet Management and Machine Guidance Systems

While machine guidance and fleet management systems (FMSs) have undoubtedly proven their ability to drive improvements in productivity and accuracy on their own, their capabilities and value can be increased dramatically when integrated together.

For example, mines wishing to manage and improve their material blending can leverage a robust FMS (such as our DISPATCH® system) in combination with a high-precision machine guidance system (such as out ProVision® system for loading equipment). The improved shovel accuracy afforded by the machine guidance system reliably ensures that the material loaded into trucks aligns with the mine plan, while the FMS ensures the correct routing of that material to appropriate stockpiles or crushers.

Mines that leverage the DISPATCH FMS also have the optional Blending and Dynamic Material Inventory Reporting modules at their disposal, which further optimize the material blend by:

  • Automating blending at crushers
  • Maximizing stockpile management and efficiency
  • Reducing material re-handle
  • Monitoring and tracking grades
  • Tracking the amount of material at blast, stockpile, and dump locations

Implementing a high-precision machine guidance system for drills, which provides continuous navigation to help drill operators satisfy accurate hole patterns, depths, angles, and spacing, can further improve the reliability of the material being dug.

Real-world example:
A nickel mine in Brazil recently relied on the ProVision system for loading equipment, the DISPATCH FMS, and its optional Blending and Dynamic Material Inventory Reporting modules, to improve their material blending. As a result of the integrated technologies, the mine was able to reduce their ore dilution by more than 2%, representing a 1.1% increase in material grade output and an estimated $5.7M in additional revenue per year.

The ProVision system for drills can optimize material fragmentation and resource management by ensuring the right material is blasted, and with the appropriate explosives. This ensures that the mine is extracting the desired grade and material type, while improving digability for shovels at the dig face and minimizing stoppages at the crusher as a result of incorrect blends or improperly-fragmented material.

Integrating fleet management and machine guidance systems can also help with any reconciliation efforts that a mine must sometimes undertake to explain deviations from plan.

“With fleet management and machine guidance, we can now say, with a pretty strong level of confidence, that we moved X many hundreds of thousands of tonnes, from this location to this location,” explains Steven Peugh, Global Sales Manager for Modular Mining. “This confidence can help miners troubleshoot reasons they may not have moved as much ore as planned by streamlining and reducing the entire reconciliation process, allowing them to instead investigate their recovery rates, grades, and other factors that may have led to the deviation from plan.”

Connecting 3rd Party Mining Systems

We recently launched a series of APIs designed to enable the DISPATCH and ProVision systems to communicate bidirectionally with 3rd party systems, thereby enhancing functionality at both ends.

By exchanging data and consolidating it into one common language, the APIs can help mining organizations dramatically optimize their production, equipment uptime, efficiency, and more.

So far, we’ve developed APIs for:

Supervisory Control, via the Core API

The Core API exchanges data between the DISPATCH and/or ProVision systems and any supervisory and control system, such as Enterprise Resource Planning (ERP) systems like SAP.

The API enables immediate publication of production, time tracking (for time model usage), and dispatcher input event notifications, and allows for a complete feedback loop among external or downstream systems. It also increases modelling accuracy within third-party systems, thereby helping to improve plan compliance.

Sharing data between supervisory systems and production systems, in real time, enables the API to help operations optimize their overall productivity. But it’s not just about productivity – “Maintenance departments can also leverage the API to optimize their workflows,” explains Mark Webb, Global Solutions Manager at Modular Mining.

“Integrating DISPATCH and ERP data enables us to use business logic to determine what to do with a ‘down’ equipment status.”  The API enables the sharing of such key information as equipment location at the time the unit was put into ‘down’ status, and the name of the operator who put the unit down, among many other datapoints.

“For a maintenance crew, a downed asset’s location isn’t always obvious,” says Webb.Having the location information via the API helps maintenance crews optimize their workflows because they’re not having to track these units down. Likewise, knowing who the operator was at the time the unit was downed, and being able to talk to that operator – to identify any smells, sounds, unusual movements, or other details that occurred when the operator downed the unit – can help maintenance teams further their fault diagnostic efforts and get equipment back up and running much faster.

Crusher Management, via the Crusher API

The Crusher API uses Supervisory Control and Data Acquisition (SCADA), Programmable Logic Controller (PLC), and DISPATCH FMS data to optimize productivity by reducing queues and bottlenecks at the crusher.

The API provides real-time visibility into crusher status, performance, and feed rate, while automating advancements of crusher-related load and haul cycle states.

It enables the DISPATCH FMS to redirect trucks to stockpiles and mitigate the effects of unnecessary queuing at the crusher (such as fuel and time waste, and the potential for vehicle-to-vehicle interactions as a result of too many trucks squeezed into a confined area).

The API also enables the monitoring of bin levels in real time, reducing black belt losses by calling for ROM feed on demand.

“Black belt heavily impacts downstream systems,” says Webb. “With the Crusher API, we’re trying to get that ‘just in time’ requirement, so we eliminate queuing at the crusher while maintaining a constant feed.

Aftermarket systems integration, via the Heavy Mobile Equipment (HME) Aftermarket API

The HME Aftermarket API layers information from the DISPATCH FMS with bolt-on solutions that are not part of the original manufacturer’s build, to create some decision-making logic about these solutions.

“One of the ways that operations can use this API is for identifying contaminated loads, from a tooth detection system,” says Webb. “Being able to automate the decision to reroute a truck that is suspected of carrying a contaminated load reduces risk to the crusher and potential downtime.”

Aftermarket solutions, such as a camera-based tooth detection system, fatigue management system, and proximity detection systems are excellent candidates for the HME Aftermarket API.

“Enabling the exchange of real-time information between aftermarket products and the DISPATCH system significantly reduces the lag for any potential intervention. Layering this information provides a deeper understanding and better decision logic, resulting in a safer, more efficient and productive operation,” Webb concludes.

Mine Planning, via the Machine Guidance API

The Machine Guidance API connects the ProVision system to a third-party mining application, enabling mines to bridge the gap between planning and execution, and optimizing their mining operation by enhancing the visibility between the field and mine planning department.

The API enables real-time updates to the mine planning software, rather than having to send huge chunks of data at the end of a shift or during a weekly update.

“Exporting a design out into the field is typically a manual, and, quite frankly, annoying, process to have to go through multiple times,” said Mark Webb. “It’s a laborious task, especially when it’s repeated numerous times. So what we’re trying to do with the API is create a much more seamless environment for the ProVision and Mine Planning systems to talk to each other.

“This provides the planners with a direct correlation between what they’re delivering to the field, and what’s actually occurring in the field. We see a huge potential for the planning group to be able to use this to see what’s happening in the field,” continues Webb.

Payload Management, via the Payload System API

The Payload System API layers information between the ProVision and DISPATCH systems, and third-party shovel payload monitoring systems like the Argus system, to optimize payload.

“The goal with this API is to improve payload accuracy to narrow the bell curve and get as close as we can to the target payload – and then replicate that consistently, explains Webb. The API consolidates inputs into the DISPATCH and ProVision systems, as well as truck and shovel payload data, and presents it all in a unified, single interface. “This allows us to centralize payload reporting, decrease instances of over- or under-loading trucks, and increase payload accuracy by reducing those outliers,” Webb explains.

The single display provides visual payload guidance directly on the ProVision mobile screen and eliminates the need for operators to interact with (or focus on) multiple screens, allowing them to instead focus on their task at hand:

Image: single display provides visual payload guidance directly on the ProVision mobile screen, eliminating the need for operators to interact with multiple screens.

The API also helps load and haul operations account for, and better manage, material carryback.

This shared information helps the shovel operator identify:

  1. That there’s already material in the back of the truck, and
  2. How much material there is, which they can then leverage to adjust loading practices accordingly.

“Carryback is an incredibly important part of loading a truck correctly to ensure we’re not overloading,” Mark Webb explains. “The API allows us to look at the carryback information at loading locations, as available from the OEMs of course, and then use the DISPATCH system to share that information with the ProVision machine guidance and Argus shovel payload systems.”

Mining optimization has always been the foundation of our customers’ success; it’s part of our company DNA and the cornerstone for the future of smarter, safer, more sustainable mining. The APIs help to refine mining optimization by enabling the real-time connection of technologies across the mining value chain. By connecting upstream and downstream processes, across all makes and models of equipment and technology, the APIs open the door to mine-wide optimization and interoperability.

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Intelligent Mining: Leveraging APIs to Integrate Mining Technologies https://www.modularmining.com/intelligent-mining-leveraging-apis-to-integrate-technologies/ https://www.modularmining.com/intelligent-mining-leveraging-apis-to-integrate-technologies/#respond Tue, 26 Jan 2021 17:16:00 +0000 https://www.modularmining.com/?p=12946 The recently-released Modular Mining APIs can integrate 3rd party mining technologies with DISPATCH & ProVision to unlock value at your operation. Now that we’ve progressed the commercial availability of the APIs, you’re probably eager to learn more about what they are, how they work, and what they can do for your operation.

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APIs for Intelligent Mining

A few months ago, we announced the launch of our revolutionary APIs (if you missed our press release promoting it, you can read that here). Now that we’ve progressed the commercial availability of those APIs, you’re probably eager to learn more about what they are, how they work, and what they can do for your operation.

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What is an API?

Application Programming Interfaces, or APIs, connect software applications by receiving requests from one application and sending appropriate responses to another. It’s essentially an intermediary that allows two (or more) software applications to communicate and share information that would otherwise be unavailable to either individual application.

Typing a URL into a browser, which then loads the requested page, is an example of a connection made via API.

Why use APIs?

Imagine a technology forum with a panel of experts, each with a discrete area of focus. The information to be conveyed by each expert has the potential to expand and enhance the capabilities of not only the attendees, but of the other panelists, as well. Unfortunately, as the forum gets underway, it becomes apparent that each panelist speaks a language that no one else in the room understands. There are no interpreters present, thus there’s no way for communication to take place. Although each expert has valuable data to share, and would likely benefit from the feedback received, the language incompatibility presents an insurmountable obstacle.

Now, imagine a similar situation, this time at a mine. The site’s Fleet Management System (FMS) speaks one language and the third-party applications in use all speak another. However, unlike at the forum, the required interpreters – in the form of application programming interfaces (APIs) – have been put in place.

Through the APIs, the FMS can communicate with each of the third-party applications, engaging in bi-directional data sharing that enhances functionality at both ends.

Our Vision: A Connected, Interoperable Mining Ecosystem

The Modular Mining APIs provide real-time, read-only access to various endpoints including:

Equipment positioning data

Equipment status changes

Equipment cycle state changes

In addition, the APIs provide write access to various entry points including:

Location status

Road state

Crusher Telemetry

“As industry needs have evolved, we’ve come to understand that integration is increasingly more important and that we can’t solve all problems in the mining value chain ourselves,” said Lourens du Plessis, Vice President Sales and Marketing, Modular Mining. “The APIs allow us to collaborate with other technology providers to deliver enhanced value to the industry.”

Through the API infrastructure, our industry-leading DISPATCH® fleet management and ProVision® Machine Guidance systems can interface and interoperate with applicable third-party programs, helping to increase productivity, operational efficiency, and overall value to the mines.

The release of up- and down-stream third-party integration characterizes our first step towards mine-wide optimization.

The Modular Mining APIs currently facilitate real-time (or near real-time) two-way data sharing between the DISPATCH or ProVision systems, and third-party applications in the areas of:

  • Supervisory Control (Core API)
  • Mine Planning (Machine Guidance API)
  • Crusher Management (Crusher API)
  • Aftermarket Systems Integration (Heavy Mobile Equipment (HME) Aftermarket API)
  • Payload Management (Payload System API)

To learn more about how the heightened levels of integration and increased openness facilitated by the APIs can help unlock untapped value at your operation, visit our Data Connectivity page or Contact Us.

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Mining Optimization: What does it mean to optimize your mine? https://www.modularmining.com/mining-optimization_what-does-it-mean-to-optimize-your-mine/ https://www.modularmining.com/mining-optimization_what-does-it-mean-to-optimize-your-mine/#respond Tue, 22 Sep 2020 21:34:38 +0000 https://www.modularmining.com/?p=12015 Optimization is the cornerstone of our customers’ success. It’s the foundation of our business, and the future of it, too – but what do we really mean when we say, ‘optimization’? What is optimization? What isn’t optimization? Why does it matter? Over the course of this blog series, we’ll resolve these questions, and more, as we dig deeper into understanding why mining optimization is so important to our customers’ success.

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Mining Optimization Series: Part 1

What does it mean to optimize your mine?

Optimization is the cornerstone of our customers’ success. It’s the foundation of our business, and the future of it, too – but what do we really mean when we say, ‘optimization’? What is optimization? What isn’t optimization? Why does it matter? Over the course of this blog series, we’ll resolve these questions, and more, as we dig deeper into understanding why mining optimization is so important to our customers’ success.

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What is optimization?

The word, “optimization,” is somewhat ambiguous; the Oxford English Dictionary defines it as: the action of making the best or most effective use of a situation or resource. For us, that has historically meant dynamic, automated truck assignments based on real-time situational information. Leveraging our industry-first and still best-of-breed algorithm, the DISPATCH® Fleet Management System (FMS) pioneered mining optimization by helping mines move more material, more efficiently.

“Our entire history, and everything we develop, centers on the principle of optimization,” says Lourens du Plessis, VP of Customer Value at Modular Mining. “The people that started this company – including a Professor of Chemical Engineering – understood how to use linear programming to optimize the production environment in the mine.”

You’ve probably heard the story: in the late 1970s, then-Professor of Chemical Engineering at the University of Arizona, Dr. James White, was visiting the nearby Phelps Dodge Tyrone Mine when he witnessed trucks idling in queues at one shovel, while other shovels sat hanging, ready to load but with no truck nearby. “There’s got to be a better way,” he famously said, spawning what eventually became our unrivalled fleet optimization algorithm, as well as our subsequent maintenance and machine guidance technologies, and the Modular Mining company as a whole.

Dr. White and his colleagues helped Phelps Dodge optimize their truck assignments in an automated and dynamic manner, which in turn optimized their fleet utilization and, ultimately, enabled them to move 11% more material on average (click here to read a 1981 article from the Silver City Daily Press). While automating truck assignments still drives much of the logic within today’s version of the DISPATCH FMS, the algorithm has evolved to consider more data and provide better granularity than we could decades ago.

By considering more constraints (which are continuously changing) and collecting more data related to locations, road and weather conditions, shovel priorities, crusher capacities, blend constraints or targets, travel speed uphill vs. downhill, trucks with varying performance or speed capabilities, and more, the DISPATCH system’s optimization capabilities have evolved to help miners achieve their specific goals.

But optimization is not just a matter of a really good algorithm. It also requires people, and the volition or commitment of those people – on both the mine side and the technology side.

“Without these three factors, you can’t have optimization,” says du Plessis. “You won’t get optimization unless you want it.

What isn’t optimization?

The key to mining optimization is in an FMS’s ability to make the best decision, quickly. Systems that simply measure or track the movement of material from a particular loading location to a particular dumping location can typically offer cost-effective production tracking, but they don’t actually optimize an operation. Simply put, they don’t make decisions or offer targeted insights that improve decision-making and, ultimately, operational performance – and therefore result in unresolved inefficiencies and unrealized value.

Typically, one of these systems will “lock” one piece of equipment to another and trucks will run between the same shovel and the same crusher for an entire shift. This process is typically decided by the shift supervisor, based on their understanding of their goals for the oncoming shift. But the process can be very inefficient and prone to human bias, since it’s based on personal judgement rather than objective computed calculations. It also can’t account for upset events – so an unexpected hose failure on a shovel or poorly-executed operator break can wreak havoc on a mine’s ability to meet their shift production goals.

Without Optimization

  • Trucks queue at shovels, often as a result of locked equipment assignments
  • Idle trucks waste unnecessary fuel, driving higher operational costs
  • Unproductive trucks threaten achievement of production goals

With Optimization

  • Trucks arrive at shovels just in time to be loaded (as a result of dynamic equipment assignments)
  • No (or minimized) truck idling saves fuel and money
  • Increased truck and shovel productivity enables mines to hit  production targets

When it comes to fleet management, optimization means ensuring that trucks arrive at shovels just in time to be loaded,” says Neil Ferreira, Modular Mining’s Associate Director of Product Strategy. “After it’s dumped, a truck will automatically be sent to the most opportune loading location, so there’s no static allocation of truck routes, as is required from production tracking systems. This dynamic and automatic assignment capability is where you get the efficiency gains.

A large iron ore mine in Brazil recently experienced this first-hand. After working with our consulting team to unlock nearly all of their equipment, they increased their productivity by more than 5%.

While wide-scale locking of equipment to specific routes is not generally a good practice when trying to optimize mine production, sometimes it’s necessary to lock a few trucks and/or shovels.

If a miner wants to build up a stockpile with a particular grade or material, for example, the dispatcher would likely lock the trucks carrying that material so they can only dump at that stockpile.

While many FMSs provide this capability, the problem with locking some or all equipment is that it’s often overused to the point of negating the optimization algorithm.

Consequently, mines that run their fleet management systems predominantly in “locked” mode achieve similar results to those using a simple production tracking system.

Running more trucks, or running them faster, isn’t necessarily optimization, either.

“By adding trucks, you may not achieve much more except for increased queuing time and operating costs,” says Ferreira. “A truck that travels faster, only to wait in line at the same shovel, just wastes more fuel.

Why does mining optimization matter?

Minimizing equipment idle time and shovel hanging time is one of the most prominent ways in which optimization can improve a mining operation’s processes and profit.

“By leveraging linear programming to space trucks evenly in the production environment, and thereby eliminating truck queues, optimization has a direct impact on a mine’s bottom line,” says du Plessis. “The trucks no longer have to sit idle, waiting, burning fuel. Everything’s nicely spaced out, and you have optimized use of those trucks. In many cases, you discover you have too many trucks, or too few – so by applying mathematics to the mining context, optimization can directly help a mining company’s bottom line.”

For example, a mine in Wyoming, USA, saved nearly $1 million in fuel costs by leveraging the DISPATCH system to limit their truck idle time and improve their operator practices.

“You should only use the equipment you need to meet your goals,” Ferreira continues. “Within the optimization process, the DISPATCH system will calculate the number of trucks that are required to achieve a particular goal throughout the shift, based on how the performance is going.” That gives the mine the opportunity to park unneeded trucks, which provides an extreme cost savings and further minimizes the potential for queues.

A direct example of this comes from the AGD Diamond Mine, in Russia, which dramatically reduced their truck queues at the crusher, and resulting idle time, after working with our support team and leveraging the DISPATCH FMS to optimize and automate operator assignments.

Similarly, after conducting an ROI analysis to determine whether to purchase a new haul truck or to instead implement the DISPATCH FMS’ optimization capabilities, the Copper Mountain Mine, in British Colombia, Canada, found that the FMS helped them realize a 4% hourly production increase – the equivalent to the volume of material moved by an additional 1.04 haul trucks – without the $4.2 million price-tag of a new truck. (Click here to read more about this success via an article published in International Mining.)

Optimization is the golden thread – it’s woven into everything we do,” says du Plessis. “Everything we develop, and all of our consulting offerings, are tied back to optimization and helping our customers maximize the use of their assets. It’s in our DNA, and it’ll be just as important to us tomorrow as it is today.”

Miners have a responsibility to deliver a certain quantity and quality of material to their customers for processing. Therefore, being able to ensure they deliver only what’s needed serves as a great cost control method because they don’t need to treat more material than necessary, and they avoid over- or under-delivering on quality. Optimization helps mining companies manage, track, and plan for their material movement with much more granularity and accuracy than simple production tracking systems can, ensuring their ability to deliver precise quantities and qualities.

While this initial post in our Optimization blog series highlights some of the primary benefits of optimization, there are many more. Next time, we’ll dig into those additional benefits, including the value that can be unlocked by pairing the DISPATCH FMS with other technologies and leveraging that data to expand mining optimization across the value chain.

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Modular Mining Australasia and MineWare Australasia to co-locate in Brisbane https://www.modularmining.com/relocation-announcement_modular-mining-australasia-and-mineware-australasia-to-co-locate-in-brisbane/ https://www.modularmining.com/relocation-announcement_modular-mining-australasia-and-mineware-australasia-to-co-locate-in-brisbane/#respond Wed, 29 Jul 2020 19:30:44 +0000 https://www.modularmining.com/?p=11943 Modular Mining and MineWare, both technology-focused subsidiaries of leading mining OEM Komatsu, have announced plans to move their respective Australia-based offices to a new shared facility.

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Modular Mining and MineWare, both technology-focused subsidiaries of leading mining OEM Komatsu, have announced plans to move their respective Australia-based offices to a new shared facility.

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“This is an exciting opportunity for two Komatsu technology companies to work together under one roof,” said Greg Sweeney, General Manger, Modular Mining Australasia. “The move to a central location in the mining hub of Australia will serve as a catalyst to drive growth and innovation via strong technological alignment and in-person collaboration,” he added.

Although the companies will continue to operate as individual entities, the common technology-focused facility will expand the opportunity for tighter development synergies, increased delivery of value, and improved customer communication.

“Together, we are working towards one common goal – to provide our customers with high-quality, interoperable technologies and automated systems that help solve complex mining challenges, improve safety, and increase sustainability,” said Chad Wamsley-Taylor, Vice President, MineWare Australasia.

Chad Wamsley-Taylor, VP – MineWare Australasia, and Greg Sweeney, GM – Modular Mining Australasia, will oversee operations of the new co-located office

MineWare has completed their move to the shared facility, while Modular Mining, which began the transition from Tuggerah to Brisbane earlier this month, will continue the business relocation plans throughout the first quarter of 2021.

To continue servicing their customers in the western part of the region, Modular Mining will maintain its current customer service center in Perth.

Want to learn more?

Media Contacts:

Patricia Browne
Manager, Marketing & Communications
Modular Mining
media@mmsi.com

Clare Masters
Marketing Director
MineWare
c.masters@mineware.com

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Driving the Future of Mining Automation https://www.modularmining.com/driving-the-future-of-mining-automation/ https://www.modularmining.com/driving-the-future-of-mining-automation/#respond Tue, 14 Apr 2020 14:22:30 +0000 https://www.modularmining.com/?p=11093 The post Driving the Future of Mining Automation appeared first on Modular Mining.

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By Michael Lewis, General Manager for Komatsu’s Technology Interoperability Group

If you ask a room full of mining professionals what they think of when they hear the phrase, “the future of mining,” chances are that most of them will immediately think of automation. They might even think of a specific product, such as Komatsu’s autonomous mining trucks that have recently made headlines for having moved well over 2 billion tons at sites across four continents. And we agree – mining automation, and the autonomous trucks that are helping to advance it, are critical to our industry’s future.

But automation in mining goes far beyond unmanned trucks. In fact, a complete spectrum of automated functions, equipment, and systems, currently exists. We look at the journey to full autonomy as having the following phases or levels:

Full Operator Responsibility

Level 0

Manual
Operator is fully responsible for all functions

Level 1

Operator Guidance
Provides feedback to improve task execution

Level 2

Partial Automation
Limited functions are controlled by system with operator able to resume control

Level 3

Conditional Automation
Core functions automated, operator required to intercede as needed or for complex functions

Full Vehicle Responsibility

Level 4

High
Automation

System able to execute core functions; intervention only required for complex functions

Level 5

Fully
Autonomous

All functions automated, system able to manage significant environmental uncertainty or system failures without external intervention, performance exceeds manual in all scenarios

To maximize the opportunities and potential that exists with furthering automation in mining, Modular Mining’s parent company, Komatsu, recently created the Komatsu Technology Interoperability Center of Excellence; a group based in Tucson, Arizona focused entirely on driving product strategy and developing roadmaps for technology and automation. These in-development strategies and roadmaps aim to include the full range of mining equipment across all Original Equipment Manufacturers (OEMs) within the Komatsu family, including both surface and underground equipment, and leverage the Original Technology Manufacturers (OTMs) including Modular Mining, MineWare, and Immersive Technologies.

The new Technology Interoperability group is focused on providing customers with a high-quality portfolio of state-of-the-art, integration-ready technologies and automated systems for all types of mining. The group’s vision centers on delivering innovative mine automation solutions that exceed customer expectations and provide a step change in safety and productivity. Recognizing that each mine has its own unique requirements and that customer operations span the various levels of being autonomous-ready, Komatsu is committed to developing solutions across the automation spectrum, including offerings specific to: truck spotting, assisted operation (including active blade control), autonomous drilling, and more.

With the acquisition of Joy Global in 2017, and with it, the P&H and Joy equipment lines, Komatsu now has the largest offering of system-wide solutions on the market. Our diverse groups of experts across the globe work with customers and suppliers, continually innovating to meet the needs of a rapidly evolving mining environment.

Important technologies for the future of mining automation

The pace of the technological evolution in the consumer world is driving mining’s evolution. We’re seeing faster adoption of automation technologies and enablers at mining operations worldwide. Automation capabilities in the consumer automotive industry, including the Advanced Driver Assistance Systems (ADAS) that provide lane assistance and adaptive cruise control, are becoming standard systems on new cars. The underlying technologies of these automation capabilities, including controllers, sensors, algorithms, and artificial intelligence (AI), among others, are becoming more mature, thus opening opportunities for adoption into the mining industry.

Effective mining automation solutions require interoperability, as most mines have a mixed fleet of equipment. To support that customer need, Komatsu is leading the development of an ISO standard that will help make interoperability of automated equipment a reality. Together with Modular Mining’s OEM agnosticism and a focus on both safety and sustainability, we are confident these standards will support the delivery of improved solutions to meet customer and societal needs.

Many miners have started to digitalize their processes, but the greatest optimization occurs when we can collectively break down silos, share data, and integrate solutions. To further this effort, Modular Mining is working towards integration with third-party technology partners, which will allow the company’s IntelliMine solutions and third-party systems (such as mine planning and payload monitoring systems, among others) to seamlessly share data with one another. Access to this previously unavailable third-party data will enable Modular Mining to streamline overall operational efficiency by enhancing the existing decision-making algorithms within a site’s IntelliMine technologies.

The advances in industrial computing and algorithm developments also allow AI and machine learning to be pushed to the “edge” of onboard equipment, enabling automatic identification and corrective action for previously unsolvable production, maintenance, and safety related problems.

As the role of automation in the mining industry continues to increase, so too does the excitement from Komatsu’s Technology Interoperability group. In the past year, our teams have had the privilege of working with many customers and internal groups to develop a new strategy and roadmap that will help drive future offerings for our customers. We are excited to continue applying advanced technology, equipment, and services to help support the mining industry’s exciting and necessary evolution to meet the demands of society for the long haul.

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Revolutionizing the Mining Industry for 40 Years https://www.modularmining.com/revolutionizing-the-mining-industry-for-40-years/ https://www.modularmining.com/revolutionizing-the-mining-industry-for-40-years/#respond Thu, 31 Oct 2019 00:37:50 +0000 http://www.modularmining.com/?p=10272 The post Revolutionizing the Mining Industry for 40 Years appeared first on Modular Mining.

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CEO Jorge Mascena reflects on 40 years in the mining industry

October 2019 marked the official 40th anniversary of the incorporation of Modular Mining Systems, Inc. This milestone occasion brings to mind how the company has grown from a three-person start-up in a small residence in Tucson, Arizona, into an industry-leading enterprise with more than 800 employees working in 10 offices around the world.

In October of 1979, a University of Arizona (UA) professor, one of his graduate students, and a UA alum envisioned using cutting-edge technology to transform the mining industry. The trio decided to take a chance, follow their convictions, and start a company.

The name they chose: Modular Mining Systems.
The product they built: The DISPATCH FMS.
The customer who gambled on that risky, yet very promising endeavor: Phelps Dodge.

Our co-founders faced countless challenges with no certainty of success. It took a lot of courage, a great customer partnership, and commitment from a few highly-talented, motivated individuals to turn that bold vision into reality. Together, the entrepreneurs embarked on a journey rooted in the idea that great value is achieved when innovative technology and open collaboration are used to overcome a challenge.

In the last 40 years, Modular Mining has invested heavily to grow our company and expand our offerings to the mining industry, leveraging new technologies, partnerships, and service models to enable our customers to achieve greater value. These offerings include an entire suite of mine management solutions, the FrontRunner Autonomous Haulage System (in partnership with Komatsu’s autonomous haulage trucks), and unrivaled services such as the Performance Assurance program. The result is impressive. We’ve enabled the movement of more than 100 billion additional tonnes of material, in over 250 mines across the globe – an amount equivalent to nearly 500 haul trucks operating continuously for the last four decades.

As a company, we have many accomplishments under our belt, but we’re far from done.

As we look to the future, we will see more automated decision making, connected data across mining operations for better insights, and a much more open approach to sharing data between technology providers, OEMs, and the industry.

By continuing to work as a team with our customers and the industry we are excited to transform our existing product portfolio and take our services to a new level with Consulting Solutions, and set the stage for leveraging data and innovation to optimize the entire mining value chain in real time.

To our employees, thank you for your dedication and for making Modular Mining such a great organization. To our customers, thank you for your trust and partnerships and for making this incredible journey possible.

Cheers to the next 40 years!

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What does 15 seconds of hang time mean for your mine? https://www.modularmining.com/what-does-15-seconds-hang-time-mean-for-your-mine/ https://www.modularmining.com/what-does-15-seconds-hang-time-mean-for-your-mine/#respond Tue, 10 Sep 2019 23:55:39 +0000 http://www.modularmining.com/?p=10063 The post What does 15 seconds of hang time mean for your mine? appeared first on Modular Mining.

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Move more tons by eliminating just 15 seconds of shovel hang time

There are many reasons that your mine will encounter hang time, including inexperienced truck operators, site requirements for bucket spotting, night time and adverse weather conditions, “cowboy” operators who are experienced yet don’t always put the truck in the right spot, and more. Regardless of the reason, hang time consumes valuable cycle time that you can’t get back. But what if you could? What does 15 seconds of hang time really mean for your mine, anyway?

Hang time resulting from truck spotting

An ideal load cycle:

  • Minimizes shovel hang time
  • Optimizes shovel swing angle
  • Maximizes trucking capacity
  • Allows for greater compliance to plan

But accomplishing this ideal load cycle is not an easy task, as the efficiency and safety of haul truck maneuvering at shovels, crushers, and dumps varies dramatically with operator skill. Increasing employee turnover and the lack of available and recruit-able skilled operators further complicates the variability of operator capability across your site.

As a result, your mine probably employs standard operating procedures geared towards the lowest level of capability to ensure a safer production; traditional practices such as bucket spotting and single-side loading can reduce the risk of truck-shovel impacts, but at the cost of productivity, as the resulting increase in shovel hang time reduces the productivity of both shovels and trucks.

Additional challenges that haul truck drivers often face in truck-shovel interactions include the difficulty of determining the correct approach to radial equipment, working in a highly distracting and very dynamic shovel area, and a lacking understanding of the shovel operator’s preferences (i.e. desired spot side, location, and heading).

Hang time as a result of bucket spot requirements:

Hang time as a result of truck re-spotting:

Defining the size of the prize

Using a conservative 15-second estimate as an example for hang time at a typical mine, let’s break down the true cost of hang time.

15 seconds of shovel hang time:

x 13 loads per hour

= 3.25 minutes of lost capacity/hour

x 20 hours per day

= 65 minutes of lost capacity/day

x 365 days

= 395 hours of lost capacity/year

x 6,000 tons/hour (shovel production rate)

= 2,372,500 tons/year

Getting to the right spot the first time

So how do you minimize shovel hang time at your mine? Active guidance to help your truck operators get to the right spot, the first time, is a good start. And several systems are available to the mining market today, which promise to do just that.

But before you invest in one of these technologies, you should make sure it will complement your existing practices, rather than seeking to replace them – in other words, don’t force your operators to stare at a camera screen when they’re used to relying on their mirrors and situational awareness.

Expecting a camera system to guide operators at night, or in dusty, rainy, or muddy conditions, is also a risky move, and may end up adding to your hang time, rather than detracting from it. And camera-based systems require yet another display to be mounted in your cab – you don’t really want that additional clutter, do you?

The ProVision® Guided Spotting system, which was recently deployed commercially at a large mine in Africa, has the potential to significantly improve both shovel and truck productivity in open pit mines by improving visibility and efficiently guiding haul truck drivers, while reversing their truck towards the shovel loading position, without guidance from the shovel operator.

The system leverages LED light bars, mounted externally near your haul trucks’ side mirrors, to encourage continued mirror use without detracting from your operators’ situational awareness. The displays are both simple and intuitive, providing high-precision, real-time guidance without distracting or requiring analysis, as soon as your truck enters the pre-defined load zone; since your truck operators don’t need to interact with the system whatsoever, they can continue to focus their attention on their mirrors and situational awareness.

Leveraging the ProVision Guided Spotting system:

This latest installation of the Guided Spotting system will help the mine increase productivity by facilitating double-sided loading, reducing the occurrence of truck re-positioning, increasing operators’ situational awareness, optimizing swing angle, and reducing shovel hang time. In the future, mine sites will also be able to use the Guided Spotting technology to optimize crusher dumping, dozer assist truck spotting, paddock dumping, pantograph guidance, lane-keeping guidance, and more.

To learn more about the ProVision Guided Spotting system,
contact your Modular Mining account representative
or click here.

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Welcome to our New Website! https://www.modularmining.com/welcome-to-new-website/ https://www.modularmining.com/welcome-to-new-website/#respond Tue, 02 Apr 2019 11:01:56 +0000 http://www.modularmining.com/?p=10229 The post Welcome to our New Website! appeared first on Modular Mining.

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What’s with the new look?

Today marks the launch of Modular Mining’s updated brand! We’re excited to roll out our fresh new look across our website, social media channels, and other sales and marketing materials.

Nearly 40 years ago, we revolutionized the industry with the release of the DISPATCH® Fleet Management System. Over time, Modular Mining has evolved to offer ground breaking solutions for maintenance management, machine guidance, wireless network communications, and operator safety. Through it all, we have remained committed to improving productivity, efficiency, and safety at every mine, and delivering measurable and sustainable value to every customer.

Over the last five years, we’ve intensified the focus on our fundamental guiding principles. We’re now doing even more to improve our service and support, to ensure that each of our customers gets the most out of our solutions. Our revamped logo better reflects what we’ve become and where we’re going, while still retaining elements of our highly-successful past.

Our redesigned website offers easier access to information about Modular Mining’s capabilities and solutions. Be sure to check our new blog (coming soon!), along with useful articles and case studies.

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