Optimize your mining activities

Lacking visibility into how your equipment is being operated, as well as frequent rework, too much time spent diagnosing maintenance needs, and inefficient load and haul procedures can limit your mining workforce performance.

By leveraging the advanced technology in Modular Mining’s IntelliMine Mine Management platform, you can break down the silos between your operations and maintenance departments and improve your personnel efficiency to achieve a truly performance driven workforce.

Encourage a performance driven workforce

Achieve desired operator behavior

Maximize your mining workforce efficiency

Minimize operator rework and manual stake/survey requirements

Boost your labor utilization

Increase tool time, decrease troubleshooting time

Optimize your procedures

Close the loop between maintenance and operations

Encourage a performance driven workforce

Achieve desired operator behavior

75%

Reduction in service brake misuse

System Used: MineCare Maintenance Management

Region: South America

Commodity: Coal

Mining Challenge

Lacking visibility into how your equipment is being operated means little opportunity to improve it. While rarely malicious, behavioral factors resulting from well-intended ideas, laziness, or bad habit can impact your equipment availability and cost your operation millions.

An abundance of false or nuisance alarms, such as those common to some proximity detection technologies, can also desensitize your operators and prevent them from ever fully adopting a new technology or behavior.

How We Solve It

  • MineCare Maintenance Management system

    Monitor real-time component condition in specific scenarios or pit locations

    • Establish custom, user-defined alarms to monitor component conditions beyond typical OEM alerts
    • Identify locations in the pit that user-defined alarms occur, as well as the time of occurrence and responsible operator
  • DISPATCH Fleet Management System

    Improve operator compliance by communicating desired actions in real time

    • Immediately transmit a FastFeedback message to operators who fail to comply with proper procedures
    • Encourage operator improvement with comprehensive KPI overviews for each shift
    • Track and log instances of operator non-compliance for internal reporting
  • MineAlert Collision Awareness System

    Improve operator adoption of technology by providing reliable alerts instead of nuisance alarms

    • Rely on intelligent path prediction algorithms and scenario-based approach to dramatically reduce false or nuisance alarms
      • Minimize the likelihood for  operator disregard with multiple levels of alerts, in increasing urgencies
      • Leverage immediate peer-to-peer communications that transmit alerts to your operators without delay
      • Improve your operators’ situational awareness by providing reliable notifications only when truly valid
  • ProVision Machine Guidance system for dozers

    Improve visibility of your dozer progress and promote consistent operator performance

    • Improve the visibility of your dozer progress and utilization through detailed productivity data, task assignment, and real-time activity monitoring
    • Promote consistent performance by providing each dozer operator with comprehensive KPI reports, available throughout a shift or at the end of a shift
  • ProVision Machine Guidance system for drills

    Gain visibility into drill pattern accuracy and timeliness

    • Monitor your drill operator accuracy and time on pattern in real-time
      • Provide your drill operator with similar visuals to encourage consistent behavior through onboard KPIs

Maximize your mining workforce efficiency

Minimize operator rework and manual stake/survey requirements

1.4M

Additional Bank Cubic Meters (BCMs) moved per year by automating shift change processes

System Used: DISPATCH FMS

Region: Colombia

Commodity: Coal

Mining Challenge

Operator inefficiency can result from a number of factors, including:

  • Employee turnover
  • Inefficient shift change processes
  • Operator inexperience
  • Weather or environmental conditions
  • Challenges associated with working at night
  • Excessive survey and staking activities

In addition to contributing more minutes to your cycle time, this inefficiency frequently requires rework, setting your mining workforce back even more.

Another common source of personnel inefficiency is in shift changes, which often result in declined production at the start and end of every shift.

How We Solve It

  • DISPATCH Fleet Management System

    Automate shift change processes to increase production

    • Monitor and control the assignment of operators to a park-up location at shift change
      • Reduce the possibility of an operator leaving equipment in undisclosed locations
      • Enable truck assignments at parkup locations near assigned end-points when trucks are unable to complete an additional full or empty load
    • Automatically assign qualified personnel to equipment before the start of a shift with the Lineup Management module
      • Communicate lineup assignments to your operators quickly and easily
      • Manually assign operators to equipment units or override automatic assignments if needed
  • ProVision Machine Guidance system for loading equipment

    Minimize uneven benches and resulting survey/rework requirements

    • Achieve target elevation the first time with intuitive elevation control
    • Minimize the need for survey teams with real-time progress-line updates and visual material delineation
    • Improve operator accuracy when working at night or in poor-visibility weather conditions
  • ProVision Machine Guidance system for drills

    Minimize re-drilling needs and improve material fragmentation

    • Precisely guide drill operators to their next hole without the need for collar placement inspection
      • Virtually eliminate the need for manual surveying with accurate collar location; you can now assign your surveyors to more value-adding priorities
    • Increase compliance to your drill plan and reduce re-drilling needs
    • Improve pit floor elevation with real-time progress updates to target depth and angle
    • Improve material fragmentation and minimize delays at your crusher or mills due to processing too-large material
  • ProVision Guided Spotting system

    Minimize truck re-spotting and equalize truck workforce performance between operators of varying skill

    • Minimize truck re-spotting events by precisely and intuitively guiding truck operators to the correct load spot on their first attempt
    • Equalize your haul truck workforce performance by enabling your least-experienced operators to perform as well as your most-experienced
  • ProVision Machine Guidance system for dozers

    Achieve accurate bench and ramp elevation the first time

    • Minimize dozer re-work and achieve precise bench grade control by providing details related to pitch and roll, current elevation, and cut/fill data that indicates the exact work expected of your operator
    • Improve your plan execution with a calibrated height gauge, which shows the precise blade adjustment necessary to achieve plan
  • MineCare Maintenance Management system

    Identify operate-for-reliability opportunities to benchmark operator performance and improve production

    • Monitor conditions that could indicate opportunities to improve operator driving practices, such as service brake application above a specific threshold or taking corners above a specified speed
    • Improve your maintenance team’s efficiency during down events by arming them with troubleshooting data to help identify the specific failed component prior to traveling from the maintenance bay to the pit

Boost your labor utilization

Increase tool time, decrease troubleshooting time

$13,700

Saved per month, per unit

System Used: MineCare Maintenance Management

Region: South America

Commodity: Iron Ore

Mining Challenge

If equipment goes down at your operation, what are the processes in place to notify maintenance? Is there any confirmation that maintenance has taken ownership of the issue? How is any of this reported back to operations?

Without contextual data to troubleshoot equipment failures, your maintenance technicians likely spend too much time diagnosing and traveling back and forth for tools and parts, and not enough time fixing.

How We Solve It

  • MineCare Maintenance Management system

    Arm your technicians with data surrounding component's failure to increase tool time and decrease troubleshooting time

    • Remotely validate and diagnose alerts to significantly reduce mean time to repair (MTTR)
    • Continuously monitor component condition to identify potential issues early and schedule maintenance as criticality requires
    • Collect real-time and aggregate data from your equipment to provide context around component failures and enable root cause analysis
      • If an asset requires immediate maintenance attention, your field technicians will know when, why, and where the equipment went into “down” status
      • Establish a “fix it the first time” mentality to minimize recurring failures
    • Reduce delays in your maintenance plan by identifying when and where upset events occur
    • Further refine your maintenance plan and practices by adding specific troubleshooting details to the  event notification
      • Outline proven procedures or OEM recommendations to improve your field technicians’ efficiency
  • DISPATCH Fleet Management System

    Improve the real-time communication between your maintenance and operations groups

    • Bridge the communication gap between your maintenance and operations departments by logging data and transmitting it automatically to central reporting
    • Provide operators with the ability to report obvious component issues via the PreStart checklist and Defects module, which communicates failed items as “defects” to your maintenance department automatically
      • Maintenance can then schedule preventive repair for appropriate time based on criticality

Optimize your procedures

Close the loop between maintenance and operations

3,533

Average additional tons moved per shift by improving dispatcher training

System Used: DISPATCH FMS

Region: Chile

Commodity: Copper

Mining Challenge

It’s difficult to optimize your mining procedures through digitization when streams of data are isolated from departments or other layers of data. Additional difficulties arise when closing the loop back to operations fails as a result of incomplete, misplaced, or misinterpreted paperwork.

Inefficient load & haul procedures, while often put in place to compensate for lacking situational awareness and potential risk, can also hinder your mining workforce performance by limiting operator productivity. Operators and dispatchers that lack recent training can also cause workforce inefficiencies.

How We Solve It

  • DISPATCH Fleet Management System

    Optimize load and haul procedures to move more material

    • Optimize your load and haul procedures to “unlock” equipment assignments
        • Dynamically assign haulage units to loading units to maximize productivity and efficiency
      • Leverage an electronic workflow to improve the data flow and real-time communications between your maintenance and operations teams
        • Allows for a single “truth” for TUM reporting and data validation between departments
  • ProVision Guided Spotting system

    Leverage dual-sided loading and improve truck operator capability

    • Increase productivity and move more material through dual-sided loading
      • Minimize safety risks by intuitively guiding truck operators to correct load spots on either side of the shovel without the need for flags, balls, hanging shovels, or other visual indicators
      • Provide your shovel operators with one-touch ability to prescribe desired loading positions relative to entrance and exit traffic flows
  • MineCare Maintenance Management system

    Continuously collect data at edge and cloud level for transparent reporting across all departments

    • Translate data into actionable information through advanced Big Data management at both the cloud and edge levels
      • Seamlessly integrate and communicate with disparate systems via the widest range of OEM interfaces in the mining industry
      • Access various datasets from multiple onboard OEM systems, operations information, tire sensors, oil analysis, and more – on demand or via automatically-generated reports

Sustain Your Value: The Big Picture

Leverage the full IntelliMine platform to truly maximize your value, sustain your improvements, and grow over time. Each system and service builds upon another, providing more value and process improvements than you can derive from just a singular technology.

Without IntelliMine

With IntelliMine Deployment

With Customer Care Package

With Value-add Services