MINING
Consulting Group( BCG).
FROM REACTIVE TO PREDICTIVE WITH INTELLIGENCE
Many mines have already adopted predictive maintenance; however, these systems often operate in isolation, relying on static thresholds and legacy telemetry. The result? Limited visibility, uncoordinated responses, and underwhelming ROI.
“ When mines deploy predictive maintenance systems, they tend to do so in isolation and rely on static thresholds. This lack of integration limits visibility and prevents coordinated responses, which erodes productivity and efficiency,” he explains.
According to research by BCG, the correct GenAI tools can lower maintenance costs by 10 %, changing how mines identify faults, request parts, and assist technicians.
Thahane explains that, unlike traditional fixed schedule methods based on legacy telemetry data, GenAI solutions can synthesise both structured and unstructured data to enable smart diagnostics, support real-time parts ordering, or enhance in-field support.
This ability to connect data across platforms is what gives GenAI a real advantage. With the proper orchestration layer in place, GenAI can process data from sensors, technician notes, and site systems in real time.
“ The differentiator is GenAI’ s ability to interpret patterns and contextualise valuable outputs from vast datasets. An orchestration layer powered by the right technology can process information from every sensor feed and every set of technician notes seamlessly, and across sites,” Thahane says.
The impact is significant.“ Using this approach, we have seen mining companies increase fleet availability by 15 % within six months, improve technician job effectiveness and optimise technician job durations by up to 20 %.”
TACKLING INVENTORY AND SUPPLY CHAIN GAPS
Even the best diagnostics are useless if the right parts aren’ t available when needed. Remote locations, poor planning, and reactive ordering can all halt production or tie up unnecessary capital in overstocked inventory.
“ Even the most advanced diagnostics fall short if parts are not available. Delays in remote sites can halt production, but excess stock will tie up working capital,” he says.“ GenAI addresses this by connecting asset health forecasts with realtime inventory, supplier lead times, and planned maintenance windows. Value is derived from ensuring optimal inventory of the right parts, purchased at the right time and price, to support planned and unplanned maintenance.”
SMARTER, SAFER, MORE SUPPORTED TECHNICIANS
Technicians are often expected to be problemsolvers, mechanics, data interpreters, and safety officers all at once. However, they are frequently let down by incomplete documentation or a lack of support across different sites.
Thahane emphasises:“ Field technicians are on the front lines when it comes to maintenance, but are often underserved. They face complex repair issues, incomplete documentation, and inconsistent knowledge sharing, especially in multi-site operations.”
“ At BCG Platinion, our specialists have designed a conversational GenAI agent specifically for field technicians, capable of translating complex fault codes into actionable steps, leveraging historical data, and identifying relevant OEM guidance, effectively providing synthesised, asset-specific support on fault identification and resolution.” Not only does this improve operational efficiency, but it also supports talent development and risk mitigation.
Thahane says,“ GenAI can help tackle the talent challenge in the mining space by embedding learning into operations, providing junior team members with guidance while saving experts time to focus on high-value work.”
“ These applications of GenAI also reduce human error and operational risk significantly by providing step-by-step guidance, flagging safety concerns, and addressing problematic conditions before they escalate.”
GETTING STARTED WITH GenAI
One of the biggest misconceptions about Generative AI is that it requires a highly digitised
December 2025 / INBOUND SA 35