The use of technology to boost productivity in mining is hardly a new trend. Back in 2017, a survey conducted by Ernst and Young with over 700 industry professionals showed that many of the top mining companies had already embarked on their digital transformation journeys. These early adopters began investing in automation and Internet of Things (IoT) technologies. However, only about 10% of the sector consists of these progressive frontrunners. The remaining 90% continue to lag behind, slow to embrace innovation.
One telling sign of this hesitancy is the continued reliance on manual and wired data collection methods instead of wireless, digital alternatives. This reflects the mining industry’s deeply rooted traditions and general aversion to risk, which often prevent investment in newer, potentially disruptive technologies.
In this article, we’ll explore how the most forward-thinking mining companies are integrating advanced technologies to gain a competitive advantage. By adopting these innovations, operations can become significantly safer, more efficient, and cost-effective.
Automation
Autonomous mining equipment has been in operation for nearly 20 years. Rio Tinto was an early pioneer, introducing a fleet of 80 driverless Komatsu trucks at its Pilbara iron ore mine in 2008, which dramatically improved productivity. Other mining giants, including BHP Billiton and Suncor, soon followed. Today, leading manufacturers such as Caterpillar, Komatsu, Sandvik, and Atlas Copco dominate the autonomous vehicle space.
These machines have transformed the mining landscape by enabling remote operation and communication with heavy equipment—particularly valuable in high-risk or hard-to-access underground environments. Most autonomous systems today are semi-autonomous, requiring limited human input for specific scenarios. These vehicles are fitted with remote control tools and cameras, allowing operators to see and act from afar. The industry’s current focus is shifting toward creating fully integrated autonomous mining systems capable of executing tasks with minimal human oversight and even achieving full automation using robotics.
Autonomous equipment enhances safety by reducing human exposure to hazardous environments. It also improves productivity through continuous operation and reduced downtime and lowers costs by requiring fewer machine operators.
Workforce tracking
Wearable technology has become a powerful tool for tracking and managing mining personnel. These devices are especially useful for maintenance crews and field inspections and play a crucial role in ensuring operator safety, particularly in underground settings.
By using RFID and other tracking capabilities, wearables provide real-time visibility of staff locations, making it easy to locate key personnel during emergencies. These systems can also help optimize operations by identifying productivity bottlenecks and improving attendance tracking.
In terms of safety, wearables integrated into a broader IoT monitoring system can significantly shorten response times in case of incidents. They can also prevent accidents by restricting access to dangerous areas. The improved management of human resources leads to more streamlined operations and fewer productivity losses due to avoidable incidents.
GPS technologies
Some mining companies have adopted GPS-enabled systems for equipment like blasthole drills and electric shovels in open-pit mines. These systems provide accurate, 3D visual representations of the equipment’s position using a Moving Map Display (MMD), helping operators guide drills from hole to hole or maintain precise digging angles—sometimes from remote locations.
Due to the harsh mining environment, these GPS components must be robust and reliable. AQUILA Mining Systems Ltd., for example, has successfully implemented GPS-based navigation in several Canadian coal and iron ore mines.
This level of precision increases operational efficiency and ensures that equipment follows the correct excavation patterns, reducing errors and material waste.
Digital twins
Managing engineering and asset information throughout the mining lifecycle has always been a challenge. Digital twin technology addresses this by creating virtual models of physical assets, systems, and operations. These real-time replicas integrate AI, machine learning, and analytics to simulate and monitor physical assets continuously as they evolve.
In simple terms, digital twins are dynamic, interactive digital counterparts of real mining environments. They offer a way to visualize and interact with operations as though you were inside a video game, enabling faster, more accurate decision-making.
For example, Anglo American Plc has adopted digital twin technology to track haulage performance at its Los Bronces site in Chile and to monitor a 500-kilometer pipeline in Brazil. These tools help identify gaps in data collection and monitoring, guiding digitization efforts where they’re most needed and impactful.
By simulating physical operations in real time, digital twins greatly enhance the management, maintenance, and optimization of mining assets.
Operational Intelligence (OI)
Operational Intelligence plays a vital role in the digitization process and in creating digital twins. It involves the use of data analytics to generate real-time insights that inform strategic decisions. In mining, this means digitizing dynamic elements like vehicles, staff, and infrastructure to monitor and optimize their performance.
OI systems aggregate and analyze both historical and live data using AI-driven tools to detect anomalies, trigger alerts, and recommend actions. They offer a comprehensive, real-time view of operations, making it easier to manage assets, coordinate teams, and prevent issues before they occur.
For example, OI can be used to track vehicle locations, monitor slope stability, or improve communication among teams via mobile platforms. These systems are designed to integrate data from multiple sources and turn it into actionable intelligence.
Wireless monitoring
Over the next five years, it’s expected that most mining operations will adopt some form of OI. Within the next decade, the use of digital twins will likely become standard. But for many mines, the first step is replacing outdated manual or cabled systems with wireless monitoring.
Wireless systems allow operators to digitize assets and track their status in real time. This is particularly important for assets like tailings dams, which are often remote and dangerous to access. Manual data collection is not only time-consuming and risky but also results in outdated information by the time it reaches decision-makers.
While installing wired monitoring systems offers some improvement, it is expensive and complex. Wireless systems provide a more practical solution, connecting sensors like piezometers to gateways that can transmit data over distances of up to 15 kilometers. These systems support constant monitoring of critical assets without the need for human presence.
Ultimately, wireless monitoring enhances safety and operational efficiency while significantly reducing labor, transportation, and installation costs. By maintaining consistent asset availability, these systems deliver a strong return on investment.
Conclusion
Embracing digital technologies—such as automation, workforce tracking, GPS, digital twins, OI, and wireless monitoring—can transform mining operations from traditional and reactive to modern and data-driven. While only a small portion of the industry has fully embraced these tools, their benefits are undeniable. Mines that adopt these innovations not only improve safety and productivity but also position themselves for long-term resilience and success in a highly competitive global market.
Very useful article with various insights in integration of technology in mining