Mining and Tunnelling are complex and hazardous operations that require advanced technology for worker safety and operational optimization. The Internet of Things (IoT) is revolutionizing the mining industry by providing real-time data insights across the entire mining process, from exploration to production, logistics, and safety. One of the key enablers of IoT in mining is eSIM (eUICC), which offers secure and flexible connectivity for IoT devices, significantly impacting mining operations. This article explores how eSIM facilitates various IoT technologies that are transforming the mining industry.

eSIM & Mining Technology

Reliable and secure connectivity is essential for IoT devices in mining to transfer data between sensors, gateways, and cloud servers. eSIMs simplify the connection and management of numerous IoT devices across different locations, even in remote and harsh environments.

eSIM integration into sensors, cameras, trucks, drills, conveyors, and other mining equipment enables real-time data transmission on factors such as temperature, humidity, pressure, vibration, and geolocation. This data optimizes production, reduces downtime, enhances safety, and improves environmental sustainability.

Benefits of eSIM for Mining

eSIM offers multiple benefits for connecting IoT devices in the mining industry, including:

Increased Flexibility: eSIMs enable dynamic switching between multiple networks based on location and coverage, eliminating the need for manual SIM card replacements.

Reduced Costs: eSIMs eliminate the management of multiple connectivity providers and contracts. Physical management and associated costs of SIM cards are also eliminated, with no need for field SIM swaps.

Enhanced Security: eSIMs employ advanced security features like encryption and digital certificates to safeguard data transfers and prevent unauthorized access.

Improved Efficiency: eSIMs provide faster and more reliable connectivity, enhancing data collection, analysis, and decision-making accuracy.

Upgraded Safety: eSIMs offer real-time insights into the location and condition of workers and equipment, aiding accident prevention, hazard detection, and emergency response.

eSIM-enabled IoT Use Cases in Mining

Some of the eSIM-enabled IoT solutions currently employed in mining are:

Real-Time Tracking and Monitoring: IoT-based systems enable real-time monitoring and tracking of people, goods, and equipment within mining environments. This enhances safety, reduces tracking time, improves coordination, and boosts performance.

Predictive Maintenance: By leveraging IoT sensors and data analytics, mining companies can detect and prevent equipment failures before they occur. Predictive maintenance reduces downtime costs and allows proactive problem resolution.

Remote Operations from Control Centers: IoT enables remote control of mining operations from a central or remote location using sensors and advanced communication systems. This optimizes operations, ensures worker safety, and maintains production speed.

Efficient Resource Management: IoT aids in monitoring, managing, and optimizing resource usage in remote mining locations. Sensors track water and power consumption, providing insights for predictive modeling, resource optimization, and waste reduction.

Environmental Monitoring: eSIM-enabled sensors measure air quality, noise, and dust levels, facilitating mitigation of mining’s environmental impact. IoT-connected sensors detect changes in water levels and pump performance, optimizing water resource usage. Predicting soil and rock characteristics minimizes waste and environmental disturbance.

Safety and Security: IoT enables real-time monitoring of workers, activities, and locations, improving safety in hazardous mining environments. Wearables and audio/video surveillance track worker movements and identify potential safety hazards. IoT sensors monitor environmental factors such as air quality, humidity, heat, and dangerous gases, ensuring safer working conditions.

The Future of Smart Sites

With the increasing adoption of IoT in smart mining, significant advancements are expected. Wearable technology, like smart helmets tracking worker biometrics, enhances safety. Robots may replace humans in dangerous tasks, reducing accidents. Connected, intelligent mines can implement advanced deep-learning algorithms to understand complex mine dynamics.

eSIM plays a vital role in IoT technology for mining, providing reliable, secure, and flexible connectivity. By adopting eSIM, global mining companies can ensure “always-on” connectivity for key technologies, streamlining operations, improving efficiency, and ensuring worker and environmental safety. The accelerated adoption of eSIM is anticipated as mining companies recognize the benefits of IoT and strive to remain competitive and sustainable.

This use-case of a prominent Australian automotive company using advanced IoT-based technologies.

The Challenge: Advanced Logistics

The lack of visibility can create several challenges for logistics companies, including:

Delayed decision-making: Without accurate and timely information about shipments and inventory levels, logistics managers may struggle to make informed decisions. This can result in delayed responses to supply chain disruptions, leading to longer lead times, missed delivery dates, and dissatisfied customers.

Inefficient operations: Lack of visibility can lead to inefficiencies in logistics operations. This can result in higher transportation costs, longer lead times, and reduced customer satisfaction.

Existing system: 

A barcode scanning process was once the only option to record every detail, it was not just time consuming; it was also a manual process and a potential source for human error.

Every process step in the chain must be reported and every wrong or missing activity record – leads to delays in the process flow.

In this case – the process includes manually scanning the ID of the staff member, then the asset at the beginning and the end of each job.

With scores of jobs complete per day, the compounding issue of time spent and record keeping errors were evident.

RTLS Solution

We have found the automotive industry to call for the most advanced hybrid Asset Tags which use a combination of GPS / Wifi and Bluetooth to accurately gather location data from assets which travel through indoor and outdoor spaces and across the country.

In supply chain management, RTLS can track the location of shipments, monitor logistics, provide real-time data on the status of deliveries and stock ready to be picked up, which can help optimize the supply chain to reduce delays and overhead costs.

Asset Tags comprising of multiple IoT-based technologies are increasingly being used in specialised RTLS systems. Primarily due to the fact that these technologies are becoming more affordable and more widely available, making advanced RTLS more accessible. By using mixed IoT-based technologies and merging the data on a cloud platform, manufacturers can create a connected ecosystem, enabling real-time data sharing for internal teams and third parties to gain better insights into their operations.

In this solution the system serves to police third party SLA’s and notify internal teams about incoming stillages which are due to be packed and re-circulated with maximum efficiency.

Take away

The system successfully provides visibility and helps to police;

• The freight company to meet and manage national delivery SLA

• Recipients to prepare for inbound delivery and quickly unpack stillages 

• Internal teams to prepare for stillage re-packing and co-ordinate with dispatch

• Dispatch team to book and arrange consignment

The RTLS system detects and records each action whilst auditing performance against business rules and notifying teams down the line of new information.

This drastically relieves the heads of each department, as the system can provide timely information about what they need to know, when they need to know it.

RTLS Solution

Given the volume of assets we proposed a comprehensive asset and inventory management system to assist in automating the service management and tracking of equipment whilst in service bays and on the floor.

Combined with a high granularity sitemap used to find and display assets across large spaces in intricate detail throughout the site, complimenting the inventory management system and enabling rapid location and recovery of misplaced assets.

The inventory management system implemented enables accurate tracking of inventory levels and reducing the costs of excess inventory, and improving asset utilization.

Take away:

The system implemented creates a significant change in large-scale electronic product manufacturing by providing accurate, real-time tracking and analysis of assets and inventory.

This allows for more efficient use of resources, optimizing production and reducing downtime.

A unknown benefit which the system uncovered was that although locating the tools and equipment was seen to be the primary point of failure and cause for capped throughput, much of the equipment was actually awaiting attention in the service bays.

An action plan was hatched to increase professional services to maintain equipment at a greater pace and order spare parts in more accurate quantities to keep the fleet in operation.

RTLS Solution

The adoption of RTLS has enabled tunnelling operations to overcome previous limitations by providing

• Real-time location and tracking information
• Smart alerts and reporting
• Improved safety monitoring efficiency
• Accuracy for the operation

With wearable solutions attached to a mandatory protective safety equipment, adoption is has low resistance and can be efficient and easy to police.

They can operate underground
Rugged hardware can endure harsh spaces
Smart TAG’s provide meaningful feedback to personnel

Here are some of the core benefits provided by IoT based RTLS systems:

Better project management: Our system provides real-time information on the progress of a project, including the location of workers and equipment. This information is used to improve project planning and scheduling, as well as monitor the effectiveness of work processes. Helping to prevent errors and reduce the risk of costly mistakes.

Enhance safety: Our system can help to identify areas of potential danger and take appropriate measures to prevent accidents.

Responsive evacuations: In the event of an emergency, the system can help facilitate a more responsive evacuation process. This can help to ensure the safety of workers and minimize the risk of injury or loss of life.

Muster point visibility: identifying and recording the attendance at muster points, which are designated areas where workers assemble in the event of an emergency. Helping to ensure that all workers are accounted for and can be safely evacuated from the site.

This case study discusses Government agencies who operate in an engineering and assembly capacity.

Where Track & Traceability is paramount in every element of workflow to ensure transparency should an enquiry be raised.

The Challenge: Chain of Custody Records 

The problem that chain of custody solves is the issue of maintaining the integrity and reliability of record keeping for later auditing events. Ensuring activities can be traced back to reveal – who – where and what took place.

• Track & Trace Assets
• Cyber Physical Security
• Project Management

Every time an asset is touched, the action must be reported to the project management system.

Existing system: 

Detailed chain of custody data and record keeping is paramount for quality control and security, however without a supervisor in each room or staff maintaining and signing off on each task, it is very difficult to maintain records.

A barcode scanning process was once the only option to record every detail, it was not just time consuming; it was also a manual process and a potential source for human error.

Every process step in the chain must be reported and every wrong or missing activity record – leads to delays in the process flow.

In this case – the process includes manually scanning the ID of the staff member, then the asset at the beginning and the end of each job.

With scores of jobs complete per day, the compounding issue of time spent and record keeping errors were evident.

RTLS Solution

This complex task is made simple using RTLS. By having each staff member where a Bluetooth ID card, our system is able to track who is in the room which provides the ‘custody’ data.

Coupled with an Asset TAG on each item, provides the assets which are being worked on.

If an asset leaves the room at the same time as the asset, a relationship is formed and millisecond accurate data can present the action.

RTLS automates the tracking process and minimizes the need for manual labor, increasing productivity and minimizing errors.

By tracking the movement of assets in real-time, RTLS can help identify and eliminate bottlenecks, optimize workflows, and improve overall efficiency.

Here are some additional benefits that real-time tracking provided for the customer.

• Improved accuracy: the system provided a more accurate and reliable record of the movement of assets. This reduces the risk of errors and discrepancies own the line.

• Increased efficiency: the system automated the tracking process, reducing the need for manual tracking and documentation. This can save time and resources and increase the efficiency of the production process.

• Enhanced security: the system provided greater security for manufacturing operations, as it can alert personnel if assets are moved or tampered with. This can help to prevent misplacement and downtime.

• Improved transparency: the system provided a clear and transparent record of the movements of assets and personnel, making it easier to approve the integrity and reliability of the data available.

Take away

Overall, the new asset tracking system provided significant benefits for their chain of custody reporting, improving accuracy, efficiency, security, and transparency in the process.

Further enhancements of this customers system includes integrations with Power BI, unlocking big data analytics allows teams to map exceptions based on highly specific rules, this provides the relevant teams with non compliance information in real-time allowing on-site teams to resolve issues before they escalate.

The steel products manufacturing process involves multiple stages, starting from raw material to finished products.

Each stage of the process must flow efficiently as there is no way to change the order of operation and tight spaces make it difficult to be flexible.

The Challenge: Specialised Tools & Equipment 

Our client manufactures a growing number of products and managing the customer orders through to dispatch is heavily time consuming.

A manual QR code scanning system was implemented however it failed to be adopted well by floor staff teams.

Too much time was spent communicating with workers to coordinating their activities – and updating customers on their order status who were often unhappy with the delays and updates provided.

Existing system: 

The manual QR scanning system which was installed quickly became unreliable due to constant changeover of staff and lack of accountability amongst new team members not following scanning protocol.

The result was poor data and difficulty in identifying and managing the weak areas of the business,

Poor operational information for management teams,
disorganised facility, leading to reduced productivity, decreased throughput and unhappy customers.

RTLS Solution

An proximity based RTLS system was proposed.

By installing receivers throughout the facility to create zones, and attaching a Bluetooth TAG to the stillage which the products were transported within, the business could accurately track orders throughout their production cycle in real time.

Then deliver check in status updates to management as orders progressed, and keep customers well informed.

• Reduce production downtime
• Increase productivity
• Better inventory management
• Improve quality control

Take away

Of all of the benefits the RTLS system provided for this client, the most important was also the most basic.

Having a large operation in a tight space meant that floor space where teams could work was heavily limited.

The RTLS system provided a digital view of the factory floor to identify product status at various stages of the operational flow, by maintaining pace, reducing bottlenecks and managing efficient dispatch. The size of the factory floor was no longer a primary concern.

ALSO – RTLS was key in solving

•  Space optimisation through better workflows
•  Improved the business by allow the manager to remain productive and work with the business units equally.
•  Alleviating search time and constant walking around site
•  Optimize production efficiency and identify downtime.

Moving forward:

Being a great success the asset tracking system was scaled up, to provide insights into inventory levels, enabling proactive planning and reducing the risk of product line failure.

Additionally, an external integration with the business CRM enabled real-time product status updates for suppliers and customers. (INTEGRATIONS)

As a side note:

IoT based system are infinitely scalable, starting with a Proof Of Value to learn about the benefits, then phased roll-outs to reach a level of data delivery automation which can further propels the business.

QLD based Motorhomes & Caravan manufacturing company  came to us with their problem statement regarding visibility of operations across their 6 manufacturing facilities where motorhome build and finishing services are performed.

Manager Steve uses a manual system of recording production flow which helps him know where each product is and oversee the operation.

The Challenge: Operational Awareness

• Improve operational insight (increase efficiency)
• Make data driven decisions (increase business performance)
• Reduce bottlenecks
• Save time looking for assets
• Remote visibility to improve business management

Goal: Visibility of operations across 6 manufacturing facilities where motorhome build and finishing services are performed

Existing system: 

• Whiteboards
• Telephone calls & emails
• Visual inspections

Effective but limited – prone to delays, errors, and downtime.

RTLS Solution

Our solution is simple and low cost, we attach an Asset Tracking Tag to each chassis and a Gateway is plugged in at each location.

From here we have real-time visibility of what is in each space and where each chasis is.

This information is shared with each department via a wall mount screen so they can see the products which are next in line and most importantly, management can quickly identify if they are falling behind.

• Real-time production flow
• Less time on foot searching
• Transparency helps keep teams synchronised
• Data provides a single source of truth
• Identify well performing departments
• Improves accountability of each department
• Enables remote management

Take away

This is an example of a low cost RTLS solution which is quick and easy to setup, provides meaningful data for the business and ties the departments together.

What is interesting about this use case is the many benefits which have transpired and respective value attributed by such a simple system.

Needless to say, the return on investment for Steve was greater than expected.

See how it works

Wirepas is a wireless communication technology that has been designed for industrial Internet of Things (IoT) applications such as asset tracking. It is a highly scalable and flexible technology that can be used for a variety of asset tracking applications across a wide range of industries.

Wirepas is based on a mesh network topology, which means that
each node in the network can act as a router for other nodes. This enables the
network to be highly resilient and self-healing, as nodes can dynamically reroute data to avoid any network disruptions.

One of the key benefits of Wirepas is its scalability. It can
support networks with thousands of devices, and because of its mesh topology, adding new devices to the network is simple and easy. This makes it an ideal technology for asset tracking applications where large numbers of devices need to be tracked across a wide area.

Wirepas is also very flexible, which means that it can be
adapted to a wide range of asset tracking applications. For example, it can be
used to track assets in industrial environments such as factories and
warehouses, where there may be a lot of interference from machinery and other equipment. It can also be used to track assets in outdoor environments such as ports and airports, where there may be a lot of obstructions and other
challenges. Wirepas is designed to be highly reliable, with data packets
being transmitted and received multiple times to ensure that there is no data
loss. This makes it an ideal technology for asset tracking applications where
data accuracy is critical. It also supports multiple frequency bands, which
means that it can be used in different regions around the world.

Wirepas is a low-power technology, which means that it is ideal
for battery-powered devices. This is important for asset tracking applications
where devices may need to operate for extended periods without needing to be recharged. Additionally, Wirepas devices can be configured to operate in
different power modes, depending on the specific requirements of the
application.

In conclusion, Wirepas is a highly scalable, flexible, reliable,
and low-power technology that is ideal for asset tracking applications across a
wide range of industries. Its mesh topology enables it to be self-healing and
resilient, while its multiple frequency bands and low-power capabilities make
it a versatile technology that can be adapted to different applications. With Wirepas, organizations can track their assets with high accuracy and reliability, enabling them to optimize their operations and improve their bottom line.

Further Benefits

Scalability: Wirepas can support networks with thousands of devices, making it ideal for asset tracking applications where large numbers of devices need to be tracked across a wide area.

Flexibility: Wirepas can be adapted to a wide range of asset tracking applications, from industrial environments to outdoor settings.

Reliability: Wirepas is designed to be highly reliable, with data packets being transmitted and received multiple times to ensure that there is no data loss.

Multiple frequency bands: Wirepas supports multiple frequency bands, which means that it can be used in different regions around the world.

Low-power technology: Wirepas is a low-power technology, which means that it is ideal for battery-powered devices and can operate for extended periods without needing to be recharged.

Self-healing and resilient: Wirepas’ mesh topology enables it to be self-healing and resilient, as nodes can dynamically reroute data to avoid any network disruptions.

Accurate data tracking: Wirepas’ reliable data transmission and reception make it an ideal technology for asset tracking applications where data accuracy is critical.

Easy device integration: Wirepas devices can be easily integrated into existing networks, making it a cost-effective and efficient solution for asset tracking.

Cost-effective: Wirepas is a cost-effective technology for asset tracking applications, as it requires less infrastructure than other solutions and can be easily scaled up or down as needed.

The implementation of a quality management system can benefit any business that is committed to providing high-quality products or services to its customers.Implementing an IoT-based asset tracking system can bring several benefits to your quality management system. Here are some ways IoT-based asset tracking can benefit your quality management system:

Real-time visibility of assets

IoT-based asset tracking systems provide real-time visibility of your assets, including their location, status, and usage. This visibility can help you to monitor your assets more effectively and make informed decisions about asset management.

Increased asset efficiency

IoT-based asset tracking systems can help you to identify underutilized assets and optimize their usage. This can lead to increased asset efficiency and reduced downtime, which can result in cost savings.

Improved quality control

Asset tracking can help to improve quality control by providing real-time data on asset usage and performance. This data can be used to identify potential quality issues and take corrective action before they become larger problems.

Better inventory management

Asset tracking can help to improve inventory management by providing real-time data on inventory levels and usage. This can help you to optimize your inventory management processes, reduce waste, and improve supply chain efficiency.

Enhanced security

Asset tracking can also help to enhance security by providing real-time data on asset location and usage. This can help to prevent theft, loss, and unauthorized usage of assets.

By implementing an IoT-based asset tracking system, you can improve your quality management system by gaining real-time visibility of assets, increasing asset efficiency, improving quality control, better inventory management, and enhancing security.IOTTAG is working closely with Australian companies to share the benefits of automated data collection through real time tracking.

Get in touch with our QMS team to learn more about how IOTTAG systems can improve your quality management system.