Haultrax’s flagship fleet management system (FMS) offering is the FleetOps module, a solution which uses GPS tracking and intelligent algorithms to compile operational data to enable miners to measure, report and improve on key metrics. The FleetControl module is a dispatching tool which can be layered with this. It compounds the value of FleetOps by allowing the user to act on their data, manage mine plan execution and time, material, and activity tracking. The solution is a lightweight system that currently only requires an interface for equipment operators.
IM reached out to the company for some insight into new features and products that have recently enhanced FleetOps functionality for customers. A major addition is Haultrax’s new FleetOps Survey Recon feature, which provides users with a web interface to record survey volumes so that FleetOps is the single source of truth for material movement.
Haultrax says it allows for more accurate tracking, as users can compare material movement data with survey volumes and adjust truck factors to ensure alignment. It also brings granular insights; maintaining per-cycle granularity while matching end-of-month survey totals. It also means more streamlined reporting, eliminating manual data extraction and post-processing with PowerBI-ready historical reporting that matches survey volumes. Collectively it enhances decision-making by permitting users to stay on track throughout the month, knowing their data reflects the source of truth.
The company told IM: “Survey is king and the source of truth used by mining customers for reporting total volumes. Surveys are generally completed on a monthly basis, and they are used to report volume movement from the pit for both business and legislative reporting. The issue with using only survey for reporting is that mine operators won’t know if they have met target until after the end of the month and therefore won’t have a grasp of how they are tracking through the month. Survey also doesn’t give per cycle granularity – only total change in volume.”
It adds: “In a traditional mining operation, tally sheets maintained by truck operators are collected every shift and aggregated to estimate how much volume is being moved. Cycles are converted to volumes using an estimate called a truck factor which considers the nominal payload of a given truck and the material density of a given material. This aggregation of truck factor then provides an estimate material movement between surveys. The issue then is that once the survey is completed the two values won’t necessarily match. The solution to this is that, as survey is taken as the source of truth, the truck factors are retrospectively adjusted for all cycles in a given survey period such that they sum to the same total as the survey. These new factors can then be used as an updated estimate for the next survey period. This means that all historic data will sum to the same totals as the survey data thus maintaining them as the source of truth.”
Ore Spotter Tablet
Ore spotters play a crucial role in ensuring the correct allocation of ore grades during loading. Haultrax has developed a new dedicated, simple interface, the Ore Spotter Tablet, that allows them to track trucks in real-time and identify which truck is being loaded by which digger. “Previously, spotters relied on tally sheets to track data, but this new solution automates and simplifies the process. By developing this solution, we enable ore spotters to capture detailed information about the material being dug and map it to truck cycles, allowing them to efficiently record data for accurate grade control. By having a single-page interface, the process remains efficient and straightforward, minimising errors and enhancing operational accuracy.”
Users can identify, track, and manage the correct material to its intended destination accurately and in real-time. “It ensures accurate location-based material tracking, improving stockpile management and ore reconciliation. Spotter and excavator operator tablets integrate together, allowing them to collaborate and record the correct information. If tablets are installed in the trucks, the ore spotter could also take on dispatching responsibilities.”
Supervisor Tablet
The Supervisor Tablet delivers real-time, focused insights on productivity and performance, giving supervisors the right information they need – without data overload. “It enables quick, informed decision-making in the field, allowing for immediate corrective action to keep operations running efficiently. By equipping supervisors with data, they can know where they are before they get there. Giving them a greater opportunity to hit their targets and get more tonnes out of their operation.”
Supervisors can monitor fleet performance, cycle times, payload data, and operator efficiency from anywhere in the pit. “With up-to-date insights on productivity and operational bottlenecks, supervisors can proactively address issues before they impact production. Unlike traditional control room monitoring, the tablet provides instant access to key metrics while on-site, ensuring quick response times. With the Supervisor Tablet, supervisors have the insights they need – where and when they need them – to drive better performance and keep operations on track.”
Algorithm update for new digital signals
Haultrax has also updated its FleetOps algorithm so that it is now able to accept additional OEM-agnostic digital inputs of Tray_Up from the Dump Switch and Is_Loaded from the Load Cell or payload weightometer systems. “This allows customers added flexibility to implement FleetOps in a way that best works for them and the way that they run their operation. These signals enable the algorithm to increase precision, handle edge cases and greatly simplify the geofence management process.”
FleetOps is built on the philosophy of being a lightweight and OEM-agnostic product, and as a result the FleetOps algorithm is built to use only hardware inputs from GPS location and reverse signals to generate detailed haul cycle data. “For conventional mining operations who perform routine geofence management this solution works well and provides detailed and accurate data. However, there are some edge cases where additional signals are required such as no reverse/drive-off loads which commonly occur for cycles dumped for road construction; and in-pit tip offs which commonly occur due to overloads or input tip offs.”
Concluding, Haultrax says it has seen an unprecedented level of enquiries in the past 12 months. Recent sales include a contractor fleet and a mid-tier garnet operation. “These are typical of our customer interest. We are currently working with potential customers who have no FMS at all, others have attempted to build something more modern than our competitors but found the last insight algorithms difficult, and then many are currently using expensive, traditional FMS options but not seeing their value.”
Alcoa’s Willowdale site, located near Waroona in Australia, was Haultrax’s first reference for the FleetOps reporting system, and the full FleetControl FMS has been successfully rolled out across the site. Prior to this, the mine relied on manual management processes which provided little visibility of team members and assets. Data availability was slow and limited, making it difficult to visualise production rates from a short-interval perspective.
With the FleetOps deployment, Alcoa has been able to achieve accurate mine plan management and real time productivity accounting, while FleetControl adds value through analysis of production data and insights as to why targets are or are not being met.
“Change management was an important part of the implementation process, hence the staggered approach to the technology deployment. This allowed the Willowdale team to adjust to the new system and address any challenges before the next level of technology was introduced.”
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