Case study

Powering the Future of Mining Through Smarter Problem Solving

Energy and Resources
Aerial view of a large open-pit mining site with excavation machinery and trucks in operation.

Challenge

A major mining corporation needed a way to systemically identify and eliminate recurring operational issues across its global mining operations.

Outcome

We collaboratively developed a cloud-native AI-enabled problem-solving platform that could be integrated into daily operations to improve safety while increasing productivity and collaboration.

A large British-Australian minerals and mining corporation, sought out a way to identify recurring issues across its global operations. Despite the presence of structured problem-solving practices under the Safety Production System (SPS), the lack of a digital solution limited scalability, consistency and cross-site learning.

 

We developed the cloud native AI-enabled problem-solving platform to embed SPS’s Practical Problem Solving (PPS) methodology into daily operations. With over 8,000 problems solved to date, the platforms helping the business to build a safer, more productive and collaborative workforce, unlocking 2.3 million tones in additional haul truck capacity and scaling SPS impact across five major programs.

 

The platform was conceived not just as a digital tool but as a strategic enabler of cultural and operational transformation. By digitising PPS, it provided a robust, collaborative and intelligent platform for root cause investigations, corrective action tracking and leadership engagement. Developed using agile methodology, the platform was rolled out by a cross-functional, distributed team across Brisbane and Kuala Lumpur. This enabled rapid feedback loops and continuous alignment with the business's evolving operational needs.

Close-up of an industrial control panel with buttons, screens, and documents on the console desk.

The technology and engineering implemented included:

  • Cloud-native architecture with React (frontend), Node.js + Express (backend) and MongoDB 
  • Azure platform services: Blob Storage, Application Insights, Azure Search AI and Queue Storage 
  • Built-in AI features for semantic search, similarity detection, suggestive root causes and automated reporting 
  • Multilingual support and a responsive, intuitive UI for all user levels, from frontline operators to executive leaders. 
Technicians monitoring industrial automation data and systems on multiple screens in a smart factory control room.

The key functional capabilities of Solver are:

  • Structured root cause analysis with 5 Whys, Fishbone and 5W2H 
  • Corrective and sustaining action assignment with real-time tracking 
  • Leadership workflows for accountability and formal case closure 
  • AI-driven semantic search to connect related problems across sites 
  • Centralised repository with automated report generation 
  • Proactive suggestions based on pattern recognition and vector search 
Heavy-duty mining trucks and loader operating at an open-pit mine under a bright blue sky with clouds.

The platform stands out due to its AI-enabled intelligence and enterprise-wide knowledge-sharing features. Unlike static systems, it leverages AI for: 

  • Semantic similarity detection 
  • Suggestive root causes based on historical case data 
  • OCR for automated input 
  • Generative AI for automated failure mode libraries 

This transformed the platform into a forward-thinking, proactive engine for sustainable improvement. For example, learnings from a single Yandi haul truck investigation were immediately reused across regions, yielding 8,000+ additional operating hours annually. 

Mining trucks and excavators working in a large open-pit coal mine with layered terrain and water nearby.

Collaborating to create tangible impact

The platform has delivered significant business value for the mining organisation, directly contributing to improved operational efficiency and productivity. By enabling faster, standardised problem-solving across sites, the platform helped unlock 2.3 million tones in additional annual haul truck capacity and reduced service time by one hour per truck, translating into major cost savings and increased uptime.  

 

The platform has become a centralised repository for knowledge reuse, embedding a consistent methodology that scales across teams and locations. This impact is already extending beyond its initial scope, as the business now integrates the platform's principles into five new Safety Production System (SPS) initiatives, including Health Check and Shift Start, reinforcing a culture of continuous improvement and future readiness. 

 

This collaboration helped us to bring our customer success through both strategic and technical rewards, applying AI-driven capabilities, such as semantic search, OCR and generative insights, within a complex industrial environment. 

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