Underground coal mining operates in a highly dynamic environment, where maintaining operational flow, optimising resource allocation, and executing plans efficiently is critical to achieving production targets and ensuring crew safety. However, many mines still rely on outdated methods such as Excel sheets, whiteboards, and paper-based systems, which cannot keep up with the rapid pace of underground changes. This lack of integrated planning and visibility creates a disconnect between weekly schedules and actual outcomes at the coal face, leading to lost production, unplanned delays, and wasted resources.

Our software suite delivers an integrated solution that addresses these challenges directly, transforming disconnected planning, execution, and reporting processes into a cohesive platform. By bridging the gap between high-level planning and on-the-ground execution, our solution enables mining operations to plan more effectively, respond dynamically to changing conditions, and ensure that every piece of equipment and resource is deployed where it is needed most. This connected approach keeps critical operations aligned with production goals, reduces delays, optimizes resource utilisation, and maintains high standards of safety and compliance across the board.

Manual and Disconnected Processes

Underground coal operations are significantly hindered by the use of manual, disconnected processes such as Excel, whiteboards, and paper-based methods for planning and execution. These tools are incapable of providing the detail and flexibility required to manage the complex and rapidly changing conditions underground. This disconnect between what is planned and what happens at the coal face widens as performance tracking. Without real-time data, maintenance backlogs grow as priorities shift, tasks are delayed, and crews operate without proper coordination. This inefficiency reduces productivity and makes it harder for mines to meet daily, weekly, and monthly objectives, ultimately impacting profitability and operational compliance. Safety protocols are often compromised as personnel are deployed based on their immediate reading of the situation, leading to siloed, uninformed decision-making. The absence of accurate, real-time data prevents timely adjustments that could reduce risks and enhance production outcomes.

Lack of Operational Visibility

A major challenge in underground coal mining is the lack of visibility across operations, particularly when managing week-to-shift activities. Fragmented systems and non-standardized processes limit the ability of mining and metals operations to gain an overview of all operational activities. Without this visibility, critical decisions are delayed, and crews often work with conflicting priorities, resulting in poor resource management, and missed production targets. The absence of a unified system makes it difficult to implement structured planning controls, leading to high operational variability. Poor communication between shifts and manual reporting only compounds the problem, creating inefficiencies that drive up costs and prevent the effective execution of the Plan-Do-Check-Act (PDCA) cycle, further impacting operational performance.

Longwall Float Challenges

The Longwall mining method is highly productive, but delays during the longwall float phase can lead to substantial production losses. Longwall panels are mined at a faster rate compared to other coal mining methods, requiring a corresponding increase in development rates. Panel extensions, stone dusting, setup of new panels, and other preparatory tasks often cause bottlenecks, leading to reduced coal output and increased costs. These task delays disrupt the entire extraction sequence, resulting in operational inefficiencies that make it harder to meet production targets. Development units that cannot keep pace with longwall operations further exacerbate this challenge, increasing Traditional offline planning tools and siloed management approaches worsen these issues causing disconnect between short-term planning and actual shift-level execution resulting in inefficient resource allocation, driving up costs and making it difficult to meet production targets consistently.

Bord & Pillar Mining Challenges

Bord & Pillar mining presents a different set of operational challenges, primarily revolving around the coordination of equipment and manpower. This method relies heavily on Continuous Miners (CMs) and Load-Haul-Dump (LHD) vehicles to drive production, but inefficient management of these resources can lead to downtime and reduced productivity. Common bottlenecks include delays in roof bolting times, poor cable management, and disruptions in loader productivity. For example, a minor delay in roof bolting can lead to a chain reaction that disrupts the entire cycle of operations, affecting the overall advance rate. Ineffective use of equipment like CMs, which account for a large portion of underground production, further complicates the situation. Addressing these challenges requires a structured system that integrates all key factors—equipment, manpower, and production data—into a cohesive plan that supports the smooth execution of Bord & Pillar operations.

Solution

Real-Time Data Utilization and Adaptive Execution

The key to success in underground coal mining is the ability to respond quickly to changing conditions. Our software supports this by serving as the central data repository on production progress, equipment status, and task completion. As crews execute tasks, they log progress and deviations in the system, providing supervisors and planners with the most current information. This data allows supervisors to adapt their shift plans based on actual performance, making decisions that optimize coal production and reduce downtime. For example, if longwall panel extensions are taking longer than expected, under-managers and deputies can use the data in our software to shift manpower or equipment resources to maintain progress on other critical tasks. Similarly, if there is an issue with a Continuous Miner in Bord & Pillar operations, supervisors can adjust task assignments to keep the operation moving while the issue is resolved. Our software ensures that these decisions are based on the most up-to-date information, reducing the gap between planning and execution and minimizing the impact of delays.

Enhanced Safety and Compliance

Our software offers the tools for teams to manage safety protocols more effectively. By offering features like safety checklists, skills management, and compliance reporting, our platform enables supervisors and under-managers to monitor safety conditions and assign tasks based on personnel certifications and qualifications. This helps ensure that the right people are performing the right tasks, mitigating risks. Additionally, our software helps supervisors track equipment status and address potential hazards. For example, if a piece of equipment is flagged for maintenance, it can be taken offline and replaced, ensuring continued operation without compromising safety. Safety protocols are embedded into shift plans, providing teams with the tools to monitor and reduce safety risks, provided they are used properly by personnel.

Cross-Functional Collaboration

With multi-user login capabilities and real-time collaboration tools, our software ensures that communication flows across all departments and teams. This fosters a strong culture of integrated work management and effective resolution of conflicts, enhancing overall operational efficiency and teamwork.

Continuous Improvement & Feedback Cycles

Our software plays a critical role in driving continuous improvement within underground coal mining operations. By capturing detailed shift data, including production actuals, equipment performance, and task completion rates, the platform enables under-managers, superintendents, and planners to analyse performance trends and identify areas for improvement. This data-driven approach helps teams refine their week-to-shift planning processes, ensuring that future plans are more accurate and better aligned with actual performance. Mining operations teams can use the data collected using our software to make informed decisions about resource allocation, task prioritization, and process improvements. For example, if delays in panel setup are consistently impacting longwall production, the data can be used to pinpoint specific issues and adjust planning to mitigate these delays in the future. Similarly, in Bord & Pillar operations, the data can be used to improve machine utilization rates, reduce downtime, and streamline cycle times, driving higher productivity and efficiency over time.