Story Series
MINING
BUSINESS VALUE
Technology innovation and the possibilities of the Cloud is driving growth at speed and scale for the mining industry. Challenges abound, though. The ‘drift’ to holistic digital transformation needs to span across production systems, the workforce and the supply chain to deliver on the promise of safe, sustainable operations.
A connected value chain, legacy systems modernization and best in class safety & health standards can help the mining industry reinvent process efficiencies and pivot itself to business transformation.
A culture of operational excellence
Our client, the world’s premier publicly traded mining company, headquartered in the US, has large scale mining operations across the globe. A technology leader in the mining industry, the organization is at the forefront of exploring emerging trends and innovation to achieve competitive advantage. The need to transform processes and operations was all encompassing, with a culture of continually striving for operational excellence aligned seamlessly to their core priority of employee safety and health.
In the journey towards ensuring automation and autonomous operations to improve efficiency and productivity, a critical enabler in the mining industry is haul trucks and the centralized systems that manage their operations. Vehicle automation using intelligent systems can be game changer for mining companies to get and stay future ready. The client’s haul trucks were one of the most expensive assets, hence there was a pressing need to ensure optimum operations and high safety. With high maintenance costs, these trucks need expert driving skills, mandatory adherence to safety standards and compliance with GPS directives from the central system.
In the spotlight - Truck haulage systems
The client was looking to streamline operations across the whole mining value chain. With safety their prime requisite, it was imperative that they achieve minimal or low Total Recordable Incident Rate (TRIR) for quantifying their safety performance. The welcome consequence would be better throughput and productivity at the mining sites.
The need of the hour
The client was looking to
Facilitate efficient, real-time responses with accurate information to enhance operating behavior
Ensure compliance with Safe Operating Practices (SOP) & correct techniques to reduce operational near-misses
and / or accidents
Enable quicker disaster recovery, higher efficiency, better analytics, real-time updates and absolute risk mitigation
Ensure optimal utilization of haul trucks and effective maintenance measures aligned with their goals rather than the haul truck OEM’s to get cost optimization and consistent throughput
Ensure compliance with regulations to encourage safe driving practices, minimize rocking the load in the truck, and enhance effective brake operations of the trucks
When the client approached Hexaware with their requirements, our team assessed their needs, analyzed the causes and set about defining the blueprint for a fail-safe solution. The roadmap was developed with focus on risk management with resiliency, strengthening the health and safety performance, efficiency in operations and processes and boosting productivity.
The Solution Spectrum
Hexaware proposed and leveraged Amaze™ for Data & AI, its proprietary state-of-the-art cloud modernization service that enables rapid transformation and deployment of data and analytics ecosystems on leading cloud platforms. Amaze™ for Data & AI modernizes the data and analytics landscape and offers more than 60% reduction in TCO towards Snowflake adoption.
The Migration of data warehouse on Teradata and Data Lake on Hadoop to Snowflake was characterized by the following milestones
Migrated applications for monitoring/ controlling mining operations including SOP violations to Snowflake
The newly migrated application for monitoring and controlling the haul trucks resulted in a significant decrease in safe operating practice violations and effective efficiency improvements. This increased sharing of timely and accurate information about risky operating behaviors and facilitated better collaboration amongst operations teams, innovation engineers, maintenance teams and equipment operators.
The Haul Truck monitoring and controlling application’s scorecard has won our client accolades and the NIOSH 2020 Mine Safety and Health Technology Innovation Award
The Results spoke volumes
Hexaware’s strategic approach and technology enabled innovation helped our client gain optimal operational efficiency to win their productivity battle and reap the benefits of improved safety, healthy performance, smart systems, reduced costs and safer haulage operations with reduction in SOP violations and marked decrease in TRIR counts.
The end result ticked all the right boxes as can be seen below.
Minimizing idle and cycle times, sudden engines failures and productivity with real-time monitoring
Nearly real-time analytics and reporting for quicker decision making
Enhanced scalability, cost efficiency and enhanced data science and analytics
Improved collaboration with different work groups across the mine
DIG DEEPER FOR MORE
DID YOU KNOW
A new haul truck costs around
6 million USD
Efficient & Real Time Responses
Safe Operating Practices
Absolute Risk Mitigation
Improved Cost
Optimization
Strict Regulatory
Compliance
Accelerate the digital journey by transitioning from Hadoop to the Snowflake Data Cloud
Marry safety and sustainability by augmenting the miners’ capabilities with sensors and memory extensions through smart technology
Task automation devices with critical risks associated with interaction between heavy equipment and light vehicles
Leverage human–machine interaction for risks reduction and mitigation
Utilize technology innovation, automation, data science and an analytics driven intelligent approach
The well-defined planned approach backed by best practices aimed to
1
2
3
4
5
This migration enabled faster on time data loading for speedier reports to drive real time inputs for quick decision making. Also, Teradata for the enterprise and Hadoop for Big Data were reaching end of life, so they were shelved.
Replaced dated Teradata data- warehouse running on-premise with Snowflake on the Cloud
Haul truck transit within mines was analysed by sensors for speed, gear, braking, pressure, truck velocity, engine rpm, transmission gear selection, GPS position, etc. This was processed using Snowflake to provide timely information regarding SOP compliance & actionable insights to the haul truck operators, supervisors and trainers.
In depth and swift analysis of data from the sensors onboard the haul trucks for optimized truck operations
Improved haul truck speeds throughout the mine
Better brake utilization while travelling and in parked state
Reduced aggressive spotting events
Elimination of rocking the load events
Drastic reduction in driving with the bed up
30000
25000
20000
15000
10000
5000
0
201903
201905
201907
201909
201911
201913
201917
20191
SITE 1
SITE 2
SITE 3
SITE 4
SITE 5
SOP Violation counts by month
Figure 1: SOP Violation counts per month at operating sites
Reduction in OPEX by ~1.3 Million per annum
Reduction in OPEX by ~1.3 Million per annum
Improved ETL Data load efficiency by 33.33%
Decrease in violation counts by more than half with efficiency improvements
4X increase in improvement of business objects report execution time
3X times improvement in analytics data load times
Independent compute layer by subject areas/ applications
Improved health
and safety of mining operations
Process and technical benefits
Primary business benefits
Process and technical benefits
Primary business benefits
Primary business benefits
Process and technical benefits
Hexaware took
the wheel
The Big Picture
The mining industry is all poised for Digital leapfrogging that can help them sustain in all-weather scenarios and have a positive impact on all growth parameters. The real life story showcased how a forward thinking organization with a people first philosophy embraced technology innovation to drive winning outcomes across the entire mining value chain. The tangible results on the social, environment and financial fronts offered by automation led digital transformation is a precursor of things to come. The mining industry has stepped up the ante. The early adopters have the competitive edge. The late bloomers are going the extra mile to catch up. The core objectives remain the same – to create a connected environment for a safe, sustainable and resilient growth story.
Reveal it
Metro 101, Suite 600,101 Wood
Avenue South, Iselin,
New Jersey - 08830
Tel: +001-609-409-6950
Fax: +001-609-409-6910
NA Headquarters
152, Sector – 3
Millennium Business Park
‘A’ Block, TTC Industrial Area
Mahape, Navi Mumbai – 400 710
Tel : +91-22-67919595
Fax : +91-22-67919500
India Headquarters
Level 19, 40 Bank Street,
Canary Wharf,
London - E14 5NR
Tel: +44-020-77154100
Fax: +44-020-77154101
EU Headquarters
#09-01, One Finlayson Green,
1 Finlayson Green,
Singapore - 049246
Tel : +65-63253020
Fax : +65-6222728
APAC Headquarters
Level 3, 80 Mount St, North Sydney, NSW 2060, Australia
Tel : +61 2 9089 8959
Fax : +61 2 9089 8989
Australia Headquarters
About Hexaware
Hexaware is the fastest growing next-generation provider of IT, BPO and consulting services. Our focus lies on taking a leadership position in helping our clients attain customer intimacy as their competitive advantage. Our digital offerings have helped our clients achieve operational excellence and customer delight. We are now on a journey of metamorphosing the experiences of our customer’s customers by leveraging our industry-leading delivery and execution model, built around the strategy - Automate Everything , Cloudify Everything , Transform Customer Experiences . Hexaware services customers in over two dozen languages, from every major time zone and every major regulatory zone. Our goal is to be the first IT services company in the world to have a 50% digital workforce.
Learn more about Hexaware at www.hexaware.com
www.hexaware.com | marketing@hexaware.com
Choosing the Right Partner was Key
Go to
top
Story
Series
A culture of operational excellence
Our client, the world’s premier publicly traded mining company, headquartered in the US, has large scale mining operations across the globe. A technology leader in the mining industry, the organization is at the forefront of exploring emerging trends and innovation to achieve competitive advantage.
The need to transform processes and operations was all encompassing, with a culture of continually striving for operational excellence aligned seamlessly to their core priority of employee safety and health.
In the journey towards ensuring automation and autonomous operations to improve efficiency and productivity, a critical enabler in the mining industry is haul trucks and the centralized systems that manage their operations. Vehicle automation using intelligent systems can be game changer for mining companies to get and stay future ready.
The client’s haul trucks were one of the most expensive assets, hence there was a pressing need to ensure optimum operations and high safety. With high maintenance costs, these trucks need expert driving skills, mandatory adherence to safety standards and compliance with GPS directives from the central system.
In the spotlight -
Truck haulage systems
DID YOU KNOW
A new haul truck costs around 6 million USD
The need of the hour
Home
A culture of operational excellence
In the spotlight
The need of
the hour
Hexaware took
the wheel
The Solution
Spectrum
The big picture
The Results
spoke volumes
Digital transformation for growth, resilience and safety
®
®
®
Read at leisure
Hexaware took
the wheel
Efficient & Real Time Responses
Safe Operating Practices
Absolute Risk Mitigation
Improved Cost
Optimization
Strict Regulatory
Compliance
Facilitate efficient, real-time responses with accurate information to enhance operating behavior
Ensure compliance with Safe Operating Practices (SOP) & correct techniques to reduce operational near-misses
and / or accidents
Enable quicker disaster recovery, higher efficiency, better analytics, real-time updates and absolute risk mitigation
Ensure optimal utilization of haul trucks and effective maintenance measures aligned with their goals rather than the haul truck OEM’s to get cost optimization and consistent throughput
Ensure compliance with regulations to encourage safe driving practices, minimize rocking the load in the truck, and enhance effective brake operations of the trucks
The need of the hour
The client was looking to streamline operations across the whole mining value chain. With safety their prime requisite, it was imperative that they achieve minimal or low Total Recordable Incident Rate (TRIR) for quantifying their safety performance. The welcome consequence would be better throughput and productivity at the mining sites.
The client was looking to
Back
Results spoke volumes
Hexaware took
the wheel
When the client approached Hexaware with their requirements, our team assessed their needs, analyzed the causes and set about defining the blueprint for a fail-safe solution. The roadmap was developed with focus on risk management with resiliency, strengthening the health and safety performance, efficiency in operations and processes and boosting productivity.
Marry safety and sustainability by augmenting the miners’ capabilities with sensors and memory extensions through smart technology
Task automation devices with critical risks associated with interaction between heavy equipment and light vehicles
Leverage human–machine interaction for risks reduction and mitigation
Utilize technology innovation, automation, data science and an analytics driven intelligent approach
The well-defined planned approach backed by best practices aimed to
1
2
3
4
5
Accelerate the digital journey by transitioning from Hadoop to the Snowflake Data Cloud
Marry safety and sustainability by augmenting the miners’ capabilities with sensors and memory extensions through smart technology
Task automation devices with critical risks associated with interaction between heavy equipment and light vehicles
Leverage human–machine interaction for risks reduction and mitigation
Utilize technology innovation, automation, data science and an analytics driven intelligent approach
Hexaware took
the wheel
The Solution
Spectrum
Hexaware proposed and leveraged Amaze™ for Data & AI, its proprietary state-of-the-art cloud modernization service that enables rapid transformation and deployment of data and analytics ecosystems on leading cloud platforms. Amaze™ for Data & AI modernizes the data and analytics landscape and offers more than 60% reduction in TCO towards Snowflake adoption.
The Migration of data warehouse on Teradata and Data Lake on Hadoop to Snowflake was characterized by the following milestones
The newly migrated application for monitoring and controlling the haul trucks resulted in a significant decrease in safe operating practice violations and effective efficiency improvements. This increased sharing of timely and accurate information about risky operating behaviors and facilitated better collaboration amongst operations teams, innovation engineers, maintenance teams and equipment operators.
Migrated applications for monitoring/ controlling mining operations including SOP violations to Snowflake
This migration enabled faster on time data loading for speedier reports to drive real time inputs for quick decision making. Also, Teradata for the enterprise and Hadoop for Big Data were reaching end of life, so they were shelved.
Replaced dated Teradata data- warehouse running on-premise with Snowflake on the Cloud
Haul truck transit within mines was analysed by sensors for speed, gear, braking, pressure, truck velocity, engine rpm, transmission gear selection, GPS position, etc. This was processed using Snowflake to provide timely information regarding SOP compliance & actionable insights to the haul truck operators, supervisors and trainers.
In depth and swift analysis of data from the sensors onboard the haul trucks for optimized truck operations
Reveal It
The Haul Truck monitoring and controlling application’s scorecard has won our client accolades and the NIOSH 2020 Mine Safety and Health Technology Innovation Award
Back
The big picture
The Results
spoke volumes
Hexaware took
the wheel
Improved haul truck speeds throughout the mine
Better brake utilization while travelling and in parked state
Reduced aggressive spotting events
Elimination of rocking the load events
Drastic reduction in driving with the bed up
Hexaware’s strategic approach and technology enabled innovation helped our client gain optimal operational efficiency to win their productivity battle and reap the benefits of improved safety, healthy performance, smart systems, reduced costs and safer haulage operations with reduction in SOP violations and marked decrease in TRIR counts.
The end result ticked all the right boxes as can be seen below.
Process and technical benefits
Process and technical benefits
Primary business benefits
Process and technical benefits
Primary business benefits
Minimizing idle and cycle times, sudden engines failures and productivity with real-time monitoring
Nearly real-time analytics and reporting for quicker decision making
Enhanced scalability, cost efficiency and enhanced data science and analytics
Improved collaboration with different work groups across the mine
Reduction in OPEX by ~1.3 Million per annum
Figure 1: SOP Violation counts per month at operating sites
SOP Violation counts by month
30000
201903
201905
201907
201909
201911
201913
20191
201917
25000
20000
15000
10000
5000
0
SITE 1
SITE 2
SITE 3
SITE 4
SITE 5
Reduction in OPEX by ~1.3 Million per annum
Improved ETL Data load efficiency by 33.33%
Decrease in violation counts by more than half with efficiency improvements
4X increase in improvement of business objects report execution time
3X times improvement in analytics data load times
Independent compute layer by subject areas/ applications
Improved health
and safety of mining operations
Reduction in OPEX by ~1.3 Million per annum
Improved ETL Data load efficiency by 33.33%
Decrease in violation counts by more than half with efficiency improvements
4X increase in improvement of business objects report execution time
3X times improvement in analytics data load times
Independent compute layer by subject areas/ applications
Improved health
and safety of mining operations
Back
Go to Home
The need of the hour
The mining industry is all poised for Digital leapfrogging that can help them sustain in all-weather scenarios and have a positive impact on all growth parameters.
The real life story showcased how a forward thinking organization with a people first philosophy embraced technology innovation to drive winning outcomes across the entire mining value chain. The tangible results on the social, environment and financial fronts offered by automation led digital transformation is a precursor of things to come.
The mining industry has stepped up the ante. The early adopters have the competitive edge. The late bloomers are going the extra mile to catch up. The core objectives remain the same – to create a connected environment for a safe, sustainable and resilient growth story.
Hexaware is the fastest growing next-generation provider of IT, BPO and consulting services. Our focus lies on taking a leadership position in helping our clients attain customer intimacy as their competitive advantage. Our digital offerings have helped our clients achieve operational excellence and customer delight. We are now on a journey of metamorphosing the experiences of our customer’s customers by leveraging our industry-leading delivery and execution model, built around the strategy - ‘Automate Everything ,
Cloudify Everything , Transform Customer Experiences . ’ Hexaware services customers in over two dozen languages, from every major time zone and every major regulatory zone. Our goal is to be the first IT services company in the world to have a 50% digital workforce
Learn more about Hexaware at www.hexaware.com
About Hexaware
Metro 101, Suite 600,101 Wood Avenue South, Iselin, New Jersey - 08830
Tel: +001-609-409-6950, Fax: +001-609-409-6910
NA Headquarters
152, Sector – 3, Millennium Business Park, ‘A’ Block, TTC Industrial Area
Mahape, Navi Mumbai – 400 710
Tel : +91-22-67919595, Fax : +91-22-67919500
India Headquarters
Level 19, 40 Bank Street, Canary Wharf, London - E14 5NR
Tel: +44-020-77154100
Fax: +44-020-77154101
EU Headquarters
#09-01, One Finlayson Green, 1 Finlayson Green, Singapore - 049246
Tel : +65-63253020
Fax : +65-6222728
APAC Headquarters
Level 3, 80 Mount St, North Sydney, NSW 2060, Australia
Tel : +61-2-9089-8959
Fax : +61-2-9089-8989
Australia Headquarters
www.hexaware.com | marketing@hexaware.com
Back
Read at leisure