Driving Efficiency and Safety in an Underground Calcium-Based Products Producer
Driving Efficiency and Safety in an Underground Calcium-Based Products Producer
Overview
A rapidly growing mid-range underground producer of calcium-based products and services in the American Midwest was confronted with new challenges. The company operates a mixed fleet of Komatsu HD465 haul trucks, CAT 775 haul trucks, and CAT 990 front-end loaders. To effectively scale and ensure safety and operational efficiency, the company turned to Symboticware’s IIoT solutions.
The Challenge
With increased production volumes, an expanded fleet, and a larger workforce, the company found the complexity of operations increasingly difficult to manage. The company needed to scale up its fleet management system, control operating costs, and maintain a laser focus on worker safety.
The Solution
Symboticware’s IIoT infrastructure was deployed across the company’s operations with the objective to prevent haul truck overloading, reduce tire wear, eliminate overspeeding, and enforce seatbelt use among equipment operators. The deployment involved the 4-Sight.ai platform, the SymBot data interface with an integrated speeding prevention model, and several proprietary and third-party sensors.
Key activities included:
- Deployment of 4-Sight.ai on a multi-make fleet of 70-ton haul trucks and loaders
- Integration of TPMS, seatbelt and active load sensors
- Third-party bucket empty or full sensors integration, connected with the work-order system
- Building an anti-speeding and anti-hard braking system
- Data management system optimization to minimize transmission cost with store-and-forward technology and WiFi/LTE switching.
Outcomes
Reduction in Load Weight Infractions: The number of load weight infractions decreased by 50% within just two years. This not only improved vehicle health but also enhanced safety across operations.
Decreased Idling: After the deployment of 4-Sight.ai, the company noticed a substantial decrease in idling by 50%. Real-time alerts to haul truck operators contributed significantly to this outcome.
Increased Employee Safety and ESG Standing: Speed infractions were reduced by 80% over two years, effectively reducing safety risks and bolstering the company’s overall ESG standing. Symboticware’s digital solutions demonstrated the potential of IIoT infrastructure in driving operational improvements and ensuring safety in the rapidly growing calcium-based products production industry.
