Digitalisation holds enormous potential to help quarries boost their competitiveness – and a tailored, partnership-led approach is key to unlocking the benefits in a practical and affordable way, says Andrey Komov, Head of Productivity for Region International at Volvo Construction Equipment.

In production applications, such as quarries, that involve repetitive jobs and moving large amounts of materials, failing to adopt a digital transformation strategy can have severe repercussions. Even small efficiency gains per tonne moved can add up to significant savings over time, improving competitiveness and the bottom line, but these opportunities can be difficult to detect with traditional methods.

And that’s not the only benefit. Real-time monitoring of machines and operator behaviour enables quarry managers to spot deviations that could lead to downtime and proactively implement safety measures to prevent accidents. Meanwhile, reduced administration and paperwork empowers workers to focus on more critical tasks, leading to increased productivity, and makes the quarry a more appealing workplace, helping to attract skilled workers in a competitive labour market.

Digitalisation is not a cure-all solution, however, rather a tool that must be used in the right way and for the right purposes. Every customer has unique challenges and objectives, and we encourage them not to face them alone. Instead, let’s work together in partnership.

Insight, Analyse, Improve and Sustain

We listen to customers carefully and take them through a four-step process – Insight, Analyse, Improve and Sustain – to develop a tailored programme that will help achieve sustainable improvements to their operations. This programme will involve various services according to the specific results customers are looking for, and in cases where we do not have a ready-made solution, we see it as an opportunity to brainstorm and develop a custom approach.

‘Plug and play’ with affordable subscriptions

That does not mean it has to be expensive, however. There is a misconception that digitalisation is only affordable for those who can put a six or seven-digit budget behind it, but we are challenging and changing this paradigm. The fact that our solutions are subscription based allows customers to start with any budget without the need for huge upfront investments. Indeed, we would recommend that customers start small and make adjustments on the go, rather than trying to make the perfect plan for digitalisation and never taking action.

To make it even easier for quarry operators, we have developed solutions that are brand agnostic. In other words, they allow customers to ‘plug and play’ with any machine, but naturally with wider functionality when integrated into a Volvo machine via our Co-Pilot platform. We are constantly learning with our customers, and our list of solutions will continue to grow over time.

Success stories with digital solutions

So far, the positive feedback has been a great source of motivation for us. One customer, who adopted our Performance Indicator and Connected Map technologies, reported saving four hours per week on reduced administration time. This translates to 208 hours per year or 26 working days of management time.

Meanwhile, several customers who have implemented our Connected Map technology have reported increased operator awareness of vehicle traffic flow. Operators can now slow down when they see a line forming to be loaded by an excavator, instead of rushing to the spot and waiting. This, combined with speed zone implementation, has led to a positive effect on fuel consumption.  Obviously, the best results can be achieved by sufficient on-site connectivity.

Furthermore, by conducting site optimisation work, we can analyse cycle data from a customer’s operations and help them identify improvement potential. In one instance, we noted a long wait time for truck loading and dumping. Further investigation revealed that the wheel loader operator was not working efficiently, causing loading to take an excessive amount of time. By creating a digital twin of the site, we were able to analyse the impact of process changes and concluded that the customer could reduce cost per tonne by 18% with minor changes in their cycle time. Operator training from Volvo was recommended as one of the next steps.

Partnering for a sustainable future

Your competitors will inevitably join this transformation sooner or later, if they haven’t already. Starting early may present challenges, but being late could be devastating for your business. We are eager to assist you in this journey as it aligns with our purpose of making this world a better place to live in. By collaborating with our customers, we can increase their efficiency and contribute to society’s sustainable development by reducing the carbon footprint and improving resource utilisation – always with people’s health, safety, and well-being at the forefront of our actions. This is why we drive innovation and work closely with our customers to create a world that is cleaner, safer, and more connected, every day.

The readiness of emergency services is crucial in ensuring the safety of communities is not greatly compromised in an emergency situation. Response times, tactical organisation and open communication channels are all key in being able to deal with a variety of risks and situations that may cause harm to people.

In order to test the emergency preparedness of local emergency services, Kumba Iron Ore’s Sishen Mine organised a Disaster Emergency Drill – whereby an uncommon emergency scenario, that may result in a disaster and mass casualties is conducted.

Partners including the SAPS, Gamagara Local Municipality Fire Brigade and Disaster Management teams, The Traffic Department, REISA, Kathu Solar Power Plant, AECI and BME, all participated in constructing a simulation of a light-duty vehicle colliding with a Bulk Explosives Truck near the main entrance of the mine.

Tshepiso Mosoma – Section Manager: Fire Prevention and Emergency Response Services at Sishen Minehighlights the importance of such exercises. “Not only are these types of drills critical in ensuring we have adequate emergency systems in place, they also create awareness regarding the types of site induced emergencies that may impact our communities.

The mine is required to comply with its Emergency and Evacuation Drills Procedure, which requires the mine to conduct this type of emergency drill annually. This is also in line with our Anglo American Social Way policy which requires our mine to comply with the policy’s Emergency Preparedness and Response requirements”.

Some of the positive insights gained from conducting the Disaster Emergency Drill were:

• It took only 14 minutes for all Emergency Response stakeholders to arrive on scene.
• It took only 11 minutes to extricate both entrapped “patients” from the LDV.
• It took only 1 minute to evacuate the emergency responders from the scene as soon as the explosives truck cargo “caught fire”.
• And access routes towards the scene, were all well managed by traffic officials and Sishen Mine Protection Services teams.

Through the simulation conducted, new controls and measures are being investigated as a way to mitigate potential disasters that could cause harm to the wellbeing of communities.

Training within the mining sector is a fast-changing field, driven by technological advancements, evolving safety standards and the need for a more skilled workforce.

Keeping up with these demands has been the focus of the Murray & Roberts Cementation Training Academy near Carletonville, combined with ongoing attention on raising safety levels in pursuit of Zero Harm. According to Tony Pretorius, Education, Training and Development (ETD) Executive at Murray & Roberts Cementation, this has meant constantly pioneering effective strategies that build excellence and discipline in the workplace.

“An important foundation for us has been the integration of technology in our training programmes, incorporating tools such as virtual and augmented reality, e-learning, and online resources,” says Pretorius. “These technologies enhance the learning experience, improve knowledge retention, and facilitate the development of digital skills essential for working with advanced mining equipment and systems.”

At the same time, he highlights the promotion of a safety culture in mining. To achieve this, the academy places a strong emphasis on cultivating a safety-first mindset among trainees. By prioritising safety in all aspects of training, the academy helps instil a culture of vigilance, risk assessment and continuous learning – aligning with best practices for workplace safety in the mining industry.

“We also ensure that our training programmes align with relevant mining regulations,” says Pretorius. “This equips workers with the knowledge and skills to adhere to the latest safety guidelines while keeping their workplace compliant with regulatory requirements.”

An example of how digital technology has been leveraged in the learning space, he points to the academy’s use of virtual and augmented reality in the training process. These immersive technologies allow trainees to experience realistic, risk-free simulations of mining environments and scenarios.

“This approach not only improves knowledge retention but also enables the identification and correction of potential mistakes before they occur in real-world situations,” he explains.

Another important aspect of the modern training approach has been towards competency-based training. Here, the focus has shifted away from the mere completion of training programmes, to the more detailed assessment of competence of workers in their specific roles. The focus, therefore, is on the development of practical skills, knowledge and attitudes that lead to improved job performance and overall safety. Pretorius also points to the vital role of what were previously referred to as ‘soft skills’ – competencies which are today proving to be as important as technical skills.

“In addition to technical skills, the mining industry recognises the importance of developing skills such as communication, leadership, teamwork and problem-solving,” he says. “These skills are vital for maintaining a safe working environment, especially in high risk situations where effective collaboration and decision-making can prevent accidents and save lives.”

Beyond the daily work tasks, workers are also having to become more aware of sustainability and environmental issues. This is inevitable, as the mining industry faces increased scrutiny regarding its environmental impact.

“Training programmes now include modules on sustainable mining practices, resource conservation and waste management,” he says. “This helps ensure that workers are aware of their responsibilities and the role they play in minimising the industry’s environmental footprint.”

Multotec has developed a range of flame-resistant rubber screen panels that self-extinguishes in under 60 seconds, thereby significantly reducing the risk of fire and the associated loss of valuable production time, plant and staff safety hazards.

Multotec responded to a challenge facing iron ore producers in Australia by developing a rubber screen media solution that negates the risk of fires associated with hot work on screen decks.

Shawn Faba, Product Manager: Screening Media at Multotec, explains that while the solution was developed to meet the stringent performance and safety requirements of the Australian mining industry, other mining operations across the world would also benefit from its adoption.

Multotec’s flame-resistant panels have been scientifically developed in collaboration with international academic institutions and raw material suppliers. The product has been tested under controlled laboratory conditions, certified accreditation trials, as well as on a number of sites in real world conditions.

Significant potential benefits

“When we consider an interruption to any production environment, the downtime could easily translate in revenue losses that run into millions of dollars. For example, in Australia, mining houses are tonnage-driven, meaning when you have unplanned downtime of two hours, it could translate to the loss of millions. Fires in the plant can shut down whole modules for weeks at a time. Australia’s miners operate in campaigns – for instance, they’ll operate for three months and then they’ll do maintenance. They don’t stop haphazardly.

“Our product has undergone rigorous testing and has been confirmed to operate continuously to fit existing shutdown campaigns, meeting the mining industry’s stringent requirements. Ensuring high-quality equipment is essential to minimise downtime. This is especially beneficial for plants that operate around the clock, as interruptions can be costly and disruptive,” says Faba.

Developed with safety in mind

“To make the rubber screen panels flame-resistant, we modified the chemical composition of the raw materials used to manufacture the panels. However, the flame-resistant screen panels can be used without compromising on efficiency, compared to conventional rubber screen media,” adds Faba.

He notes that Multotec is proud of the fact that its flame-resistant rubber screen media has received international acceptance and is in use at processing plants of some of the world’s leading iron producers. The flame-resistant screen panels can be used in all screening applications for a variety of duties, both wet and dry.

Fit for any screening-related application

“While we currently supply the flame-resistant rubber screen panels for iron ore screening applications in Western Australia, these panels can also be used in any screening-related application. They can be used extensively in all mineral processing applications, such as coal, iron ore, copper, platinum, diamonds, manganese, and zinc, among others.

In addition to providing the greatest level of fire safety, Multotec’s flame-resistant panels also increase optimal screening performance and plant availability, are available in hard (PD70) and soft (PD45) durometer rubber, and remain robust and extremely reliable under the toughest mining conditions.

Murray & Roberts Cementation emerged as a shining beacon of commitment to safety at the annual Murray & Roberts Group’s CE Safety Recognition awards in June. These awards, which spotlight various operations across group companies, recognised Murray & Roberts Cementation for its exceptional safety  performance. As a leading underground mining contractor, the company has several projects under its belt that affirm its dedication to safety and the ultimate goal of achieving Zero Harm.

One of its standout projects is the Venetia Underground Project (VUP). Collaborating with De Beers Group, Murray & Roberts Cementation played a pivotal role in developing and equipping this underground mine which has seen the transition of Venetia Mine from an open pit operation to an underground mine. Hard work and emphasis on safety by the VUP team earned the project the accolade of ‘Best Employee Participation Programme (Leading Indicator Reporting)’.

Trevor Schultz, Risk Executive at Murray & Roberts Cementation, explained the significance of leading indicators. “These are proactive and preventive measures that grant crucial insights into the safety performance of a project. They also act as an early warning system, shedding light on potential issues in a given work environment.”

In another feather in Murray & Roberts Cementation’s cap, the Palabora Mining Company Lift II project was awarded with the ‘Best Major Incidents Prevention Programme’. This was in acknowledgment of their exceptional work in both sub-categories being Critical Control Verifications and Critical Control  Assurance Audits. “Significantly, this project recently made headlines when, at the end of July 2023, it achieved a monumental feat by reaching the 1000-metre mark in its assignment to sink a 1200-metre ventilation shaft at PMC,” Schultz says.

The accolades didn’t stop there. The Matla Mine Relocation Project was lauded with the ‘Best Safety Performance at Project Level’ award, thanks to its stellar 12 months rolling TRCR performance.

In addition to this award, this project had zero work related injuries during its 22-month duration.

Schultz was proud to announce that a whopping 14 of the company’s projects were bestowed the title of Zero Harm Projects, meaning they had zero recordable cases. Such an impressive statistic doesn’t come easy. Schultz believes it’s the unwavering commitment from every single individual, from the full workforce on the ground to management, that has made this possible.

In conclusion Schultz emphasises the company’s resolute focus on training and developing its workforce. This is rooted in the belief that to truly embed safety and Zero Harm principles, it should become an integral part of everyone’s daily tasks on site. The recent recognitions stand as a testament to the company’s success in this endeavour.

Mining companies face significant safety risks associated with the use of nyaope and cannabis among their employees, jeopardising both the well-being of workers and the overall safety of operations. These substances can severely impair users’ ability to concentrate, posing challenges to maintaining focus during work. To ensure the safety of mineworkers, minimise incidents of injury, and maximise productivity, mining companies should consider adopting saliva testing as a more suitable method of screening. Saliva testing offers shorter detection periods indicating recent usage when compared to urine testing. Its sample collection process is less invasive, making employees more willing to comply with testing requirements. Furthermore, drugs can be detected in saliva within minutes of usage, enabling quicker identification compared to urine samples, which may take up to 72 hours to reveal drug presence. Embracing saliva testing can effectively accelerate the detection of drug use among mine employees, promoting a safer work environment.

Legislative necessity for testing

The Mine Health and Safety Act (MHSA) is the primary legislation that regulates health and safety in the mining industry. The MHSA requires mine owners to take all reasonable steps to prevent accidents and injuries, including the prevention of drug use. The Occupational Health and Safety Act requires employers to take all reasonable steps to prevent accidents and injuries, including the prevention of drug use.

Dangerous substances

Nyaope and cannabis are both drugs that can have a significant impact on a person’s ability to work safely and effectively. Nyaope is a dangerous and highly addictive drug that is made from a mixture of heroin, rat poison, and other substances. Worryingly, nyaope is increasingly mixed and sold with cannabis, often without the user’s knowledge which results in addiction, and  can cause a number of health complications, including respiratory and heart problems as well as mental health problems. Nyaope can also impair a person’s judgment and coordination, which can lead to accidents and injuries in the workplace. A great concern surrounding nyaope is the fact that it can create a culture of addiction among several mine employees as they share the experience of smoking the substance. Furthermore, due to its harsh nature, the after-effect of the drug is so intense on an individual that it often leads to violent and aggressive tendencies among users – leading to an even more unsafe working environment.

While cannabis is a less dangerous drug than nyaope, it can still impair a person’s ability to work safely and effectively as it can cause drowsiness, impaired judgment, and slowed reaction time. These effects can make it difficult for people to operate machinery or equipment safely, and they can also increase the risk of accidents and injuries. In addition to the physical dangers, the use of nyaope and cannabis in the workplace can also lead to several other problems. These include decreased morale and productivity, increased absenteeism, and staff turnover. This is why it is important for mines to facilitate regular testing to eliminate a possible culture of using these harmful and addictive substances.

Stepping up to stem the tide of substance abuse

There are several steps that mining organisations can take to stem the use of drugs in the industry, such as implementing regular drug testing programs. Drug testing programs can help to identify employees who are using drugs and prevent them from entering the workplace intoxicated. To achieve this, mines need to implement a strategy of testing a set number or percentage of employees per day. This method will have a much stronger and more successful deterrent effect, as word spreads through the workforce of the likelihood of being tested – helping prevent unnecessary accidents and injuries, while aiming to improve productivity and morale.

To ensure that testing programs are not perceived as having a purely disciplinary purpose, mining organisations should provide employee awareness and assistance programs. These must educate workers on the dangers associated with substance abuse and provide support to employees who are struggling with addiction through counselling, support groups, and other resources to get the treatment they need. Through awareness and testing, mining companies can establish a drug-free workplace culture by educating employees about the dangers of drugs and setting clear expectations for drug use through a written workplace substance policy. This can help to discourage employees from using drugs in the first place. It is also important for mining organisations to work closely with unions and other stakeholders in the development and implementation of drug prevention programs. This can help to ensure that all employees are aware of the dangers of drugs and that they have access to the resources they need to get help.

Advancements in testing technology

For the purposes of saliva testing, disposable multi-panel tests are no longer the only option. Today, mining organisations should be investing in a SoToxa Mobile Test System, designed for rapid drug screening and detection in oral fluid. This handheld analyser can detect the presence of six kinds of drugs: cocaine, methamphetamine, opiates, cannabis (THC), amphetamine and benzodiazepines. One of the major benefits associated with this testing system is its reporting functionality, which can be filtered by various factors such as age group and gender. This can be used to assess progress in the establishment of a drug-free workplace and measure the effectiveness of workplace interventions over time.

Drug-free workplace culture

It is important to remember that drug testing is not a perfect solution, but it is an important tool that can help to reduce the use of drugs in the workplace. It should be used in conjunction with other measures, such as employee assistance programs to create a drug-free workplace culture. Furthermore, drug testing should be fair and consistent, and should always be conducted in a way that respects the privacy of employees. By taking such steps, mining companies can help to create a safe and productive workplace for their employees.