MINING INDABA •
By connecting ERP asset registers with Aveva ' s operational monitoring, mine operators gain complete asset visibility across the mining value chain.
Integrating sensor data, such as oil temperature, vibration, operating temperature, and particle count with lab analysis data enables sophisticated predictive maintenance programs and early failure detection outside the conventional service cycle.
The ability to monitor factors such as fuel dilution and dust ingress, and the ability to predict component failure before these escalate – based on actual usage patterns, operating conditions and equipment health indicators – helps to extend asset life, increase mean time between failures( MTBF) and reduce costly catastrophic failures that can cause unplanned extended downtime, and optimises maintenance resource deployment.
This proactive detection through IT / OT convergence and the resultant predictive maintenance can mitigate the R1-million cost per day associated with downtime for repairs to a R1.4-million engine. Furthermore, fewer emergency breakdowns reduce overtime labour, express part shipments and unplanned contractor costs.
Safety and risk reduction Critically, unified data visibility directly enhances health and safety outcomes by pre-empting potential risks and hazards. Real-time alerts on overheating, pressure spikes, or structural failures in drill rigs or dump trucks reduce operator risk.
Pre-shift inspections logged in mobile devices automatically update ERP records and trigger alerts if equipment operating outside safe parameters attempts to enter production service.
When incidents do occur, integrated data enables rapid root cause analysis by correlating equipment telemetry, operator actions, environmental conditions and maintenance history from a single platform. These insights inform preventive measures that reduce incident recurrence rates.
Integrating IT systems and IoT sensors supports dust monitoring and ensures compliance with air-quality and emissions standards.
Unlocking new capabilities Beyond the operational advantages, integrated mining data paves the way for mine operators to implement and leverage the latest AIenabled capabilities. An integrated data architecture ensures AI models work with complete, contextual information spanning operational and business systems, which improves predictability models.
AI can correlate oil contamination, ECU logs, and vibration signatures to automate fault detection and make real-time recommendations for simple corrective actions to foremen. AI then monitors the effectiveness of any remedial action at a management level.
Machine learning models trained on historical integrated data can forecast production output with greater accuracy, enabling better financial planning and commitment management to customers, while the real-time replication of mining equipment, such as rigs, haulers and conveyors create digital twins for simulation and optimisation to further streamline operations.
Furthermore, scalable architecture prepares operations for future tech adoption, such as 5G underground communications, AI bots and autonomous haulage.
Strategic and competitive advantage IT / OT convergence in mining turns operational data into a strategic asset by shifting operations from reactive to predictive, reduces downtime and safety risks, maximises asset life, and creates a direct line between sensor data and business decisions, translating into measurable financial return on investment( ROI).
When enhanced with AI-driven analytics and deployed with the guidance of an experienced, qualified systems integrator with specialised expertise, this architecture delivers measurable improvements in operational efficiency, cost management, asset optimisation and safety performance.
In an industry where operational excellence increasingly differentiates market leaders from laggards, unified data visibility has become a strategic imperative. The companies that act decisively to break down data silos and establish AI-ready integration architectures will define the next era of mining excellence. •
The ability to demonstrate comprehensive safety compliance through integrated and consolidated audit trails for safety inspections, environmental monitoring, and statutory reporting also strengthens regulatory relationships and reduces exposure to penalties.
Cost reduction Integrated data enables mining companies to identify and eliminate cost inefficiencies that remain hidden in siloed systems.
When Aveva Mining Intelligence can access real-time procurement data, inventory levels and supplier performance metrics from an ERP solution, supply chain optimisation becomes proactive rather than reactive. Excess inventory carrying costs decreases, stockouts that halt production are prevented, and procurement decisions are informed by actual consumption patterns and predictive demand modelling.
Mine operators can also optimise energy consumption by correlating production schedules with equipment performance data, identifying the most energy-efficient operating parameters for different production scenarios. These incremental improvements compound across multiple mine sites and operating shifts to deliver substantial cost savings for one the operation’ s biggest cost centres.
Data-driven insights also improve budgeting for replacements and asset upgrades to support better capital expenditure planning.
Introducing the author: Marco Capazario is a business and technology leader specialising in industrial IoT, AI-driven predictive maintenance and digital transformation across the mining, heavyequipment and energy sectors. As the business unit lead at Britehouse, he drives innovation through connected sensor systems, edge computing and AI-enabled analytics that improve asset reliability, reduce downtime, and enhance operational visibility.
Marco Capazario, business unit lead and manager at Britehouse.
Capazario has led numerous digital initiatives across South African mining operations, integrating oil condition monitoring, telematics and machine-vision technologies into unified platforms such as Atajo FX and Atajo OnEdge. His work bridges the gap between OT and IT, helping enterprises unlock real-time insights, sustainability gains and measurable ROI through data-driven intelligence.
Supplied by Britehouse www. africanmining. co. za African Mining Publication African Mining African Mining • January 2026 • 49