When people talk about ‘business agility’ industries like mining and manufacturing are not usually first to mind.

But while the notion of business agility has always been associated with lean start-ups and small businesses, for mining and manufacturing organisations, being able to change with the times and embrace new technology to reduce costs and drive efficiency is now more important than ever. 

Old methods have to change – and executives across industrial manufacturing are aware of the importance of innovation and business agility.

The mining sector has been in the midst of a market challenge for the last decade thanks in part to falling prices and demand as operations are continually forced to review business plans and cut costs wherever possible.

As a result of this, more operations have investigated how new mining and industrial technology and connected equipment can help drive down unnecessary costs and improve operational efficiency, without increasing risks to health and safety.

A recent report by PwC for instance highlighted that apart from health and safety improvements, technology investment is one of the prime focusses of the main mining operators across the world in the coming years.

The mining industry continues to treat safety as a prime concern - and rightly so as mining operators strive for a goal of zero fatalities and incidents.

This safety objective however is set against a background of profits being squeezed and the resultant drive to increase operational efficiency. Even if the mining sector has moved on since those days of Haldane and his canaries, one thing that has remained constant is the harsh and unforgiving environment of mining operations. The good news is that those challenging surroundings are being tamed by the application of innovative safety technology.

While mining safety has improved considerably over the last two decades, mining is still one of the most dangerous occupations in the world.

On a routine basis, miners are exposed to a number of serious hazards: cave-ins, floods, gas explosions, wet surfaces, chemical exposure, dust, fumes, moving and falling machinery, and others.

In many instances, individual solutions are in place to mitigate these problems; but as new tools and techniques are utilised in mines, a more holistic and real-time approach to mine safety must be considered.

Despite increases in safety, mining remains one of the most dangerous and hazardous sectors to work in - mostly because of the unpredictable and often confined areas in which operatives work.

One of the major concerns within the mining sector is the integrity of the tunnels and shafts themselves. Effective monitoring is vital to ensure the integrity of the mine and the safety of the workers. Comprehensive strata control and monitoring instruments form the backbone of your mining and tunnelling operation.

Rock-bolting has replaced standing supports such as steel arches in underground mining operations as the best method of supporting and controlling strata. Using this technique has led to significantly reduced costs, greatly increased productivity and considerably higher levels of safety. To support this technique of strata support and control it is necessary to monitor the strata for mine safety.

According to statistics from the HSE, around 12,000 people in the UK die from dust inhalation related to exposure in the workplace every year and hazardous industries need to improve the working environment. While regulation is being tightened to improve working conditions, it is also the threat of legal claims that is focusing attention for managers, board members and shareholders alike.

Safety regulation across the globe has become ever more stringent as authorities have recognised the dangers associated with working in hazardous dusty environments. From mining to tunnelling and manufacturing, hundreds of thousands of individuals are working every day in high dust environments, and therefore at risk of inhaling potential health damaging toxins.

Traditional industrial sectors are not readily set up to deal with technological innovation and change, but these are also sectors in which technology and innovation can have the most dramatic impact both on health and safety, and productivity.

Many of the leaders in these sectors recognise the importance and benefits of innovation, but because they remain heavily reliant on traditional machinery and manpower, they can find it difficult to bring in new technology.

It is becoming cliché to say that technology is changing the face of business sectors all over the world, but that doesn’t mean it isn’t happening and the mining and manufacturing sectors are no different.

While traditionally labour-intensive and reliant on heavy, static equipment, smart and connected technology is now showing potential to completely change how mining and manufacturing businesses operate.

From remote and mobile environment and equipment monitoring, to real-time data and analytics to machine learning and automation, there is seemingly no end to the benefits new mining and manufacturing technology is bringing to historically industrial sectors.

Like many industries, mining is being transformed by technologies like the Internet of Things (IoT), Artificial Intelligence (AI) and machine learning.

The ability to instantly gather and analyse environmental and equipment data, and carry out real time risk and area assessments is a big benefit to large scale operations, particularly those like mining, when operatives are working in a compact, changing and potentially dangerous environment.

From increasing automation and removing human operatives from dangerous environments, to real time atmospheric monitoring and safety alerts, to more efficient operations through equipment monitoring, new connected technology is having a massive impact on the future of the mining sectors.

But are IoT and AI technologies really the beneficial platforms they appear to be? And what exactly can they do for mining operations?

The complexity of a hazardous environment has always been one of the key hurdles when it comes to managing the cost of gas detection.

Ensuring operatives remain safe in often confined spaces and unpredictable environments is essential, but the cost of monitoring for multiple gases, and replacing sensors on a regular basis can be expensive and put pressure on operational budgets.

For organisations operating in environments where just one or two gases may be present, the total cost of ownership for equipment, maintenance and replacement parts can prove to be a significant drain on budgets.

Organisations operating in more complex environments however – those where workers could be exposed to up to five or six different gases – can quickly see their costs rocket with the need for higher levels of replacement cells and a support network to match.

Traditional worker well-being has primarily focused on improving workplace safety.

Even in a legacy industry like mining, data is transforming day-to-day operations, providing greater insight into activities and enabling project managers and operatives to refine their approach.

All kinds of industries, all over the world, are changing how they work to incorporate data collection and analytics into their infrastructure to streamline processes, and inform better decision making and forward planning.

Analytics and data are not new to mining, but faced with rising costs, the scarcity of materials and rising pressure and greater demand from clients for supplies, the sector is increasingly turning to data to improve operations.

In sectors under high degrees of regulation or operating within ever changing and chaotic political or economic circumstances the ability to maintain flexible budgets, invest in new and better equipment and remain viable is essential – especially within tight margins.

Those companies operating within industrial sectors like mining, manufacturing and petrochemicals understand this better than anyone and the challenge of providing effective equipment – both in terms of life cycle, productivity and health and safety is of the upmost importance.

Suppliers similarly face the challenge of competing for the business of these companies, and many are competing on the initial price when it comes to offering low costs up-front for monitoring devices, or ventilation and dust extraction.

Real-time monitoring and instant alerts of environmental changes are a critical element of modern hazardous industrial and mining operations.

New technology like mobile ‘connected’ devices, which can be used by individual operatives, or static equipment that can be hooked up to a wider network to report on changes or potential risks to safety, have undoubtedly improved the health and safety aspect of hazardous industries.

But with so many environmental elements to monitor and with the increasing need for separate monitoring equipment, the costs of providing 360-degree safety in hazardous environments can easily spiral and cause budgetary pressures on operations.

Improving efficiency and making effective use of finances is a continual focus across industrial sectors from mining to automation to construction to petrochemicals.

But these sectors are also often placed under high degrees of regulation and constantly have to deal with changing global economic circumstances, making budgets inflexible and investment in equipment and new technology much more difficult.

And it is not just the upfront costs of providing workforces with gas monitoring devices or installing ventilation and dust extraction in hazardous environments, the on-going costs associated with the replaceable consumables in this equipment – like filters, batteries and gas cells – which are often the most challenging aspects of budget pressures.

Modern mining is all about streamlining activities and maximising operator safety through the use of flexible, sophisticated and robust technologies.

Wireless equipment allows operatives to move freely throughout the mine and conduct operations, while even static equipment is much more technologically advanced in being able to report changes of environment in real time, ensuring maximum safety at all times.

However, while the equipment used in mining has become more technical, the environments in which operatives work in have remained just as harsh and hazardous as they have always been, and the question needs to be asked, can new digital equipment handle the dusty, humid and difficult conditions in which they are needed.

Modern work environments are unquestionably safer than they have been in the past, with the rise of connected technology making it possible to detect potential problems before they arise and give early warnings to workers.

However, despite this increase in health and safety monitoring, industrial environments like mining and manufacturing inherently carry certain risks and in 2016/17, 137 people were killed in workplaces.

As the populace grows, public transport becomes more cluttered and road networks experience more congestion.

As a result, new transportation networks need to be made as quickly as possible – but in the rush, it’s important to remember that safety is the first and foremost concern, both in the sense of creating safe networks for drivers and passengers, and when it comes to the safety of operators during the project.

Safety in mining and industrial operations has improved considerably over the past decade – and indeed, the last century. Mine and industrial legislation and standards have helped to pave the way for more structured workplace safety, ensuring working conditions are optimal and that operatives are well trained to mitigate problems.

Of course, while legislation has helped to improve safety across mining and industrial operations, it is technology that has played a key role in facilitating some of the more comprehensive mining and industrial safety practices. In many respects, legislation and industrial safety technologies have worked hand-in-hand to deliver all-encompassing security for the workforce.

Artificial Intelligence (AI) is transforming business operations across the globe. Ten – or even five – years ago, the prospect of business applicable AI was a pipe dream! Now, however, AI is used across a number of industries, including: healthcare, science, manufacturing, retail, finance, customer service and – most recently – mining.

Despite being somewhat late to the AI party, Artificial Intelligence in the mining industry holds tremendous possibilities. With AI at the helm, operations can be automated, environments can be monitored in real time, machine degradation and failure can be predicted before it occurs, and operations can be streamlined – and these are just a few possibilities.

When it comes to hazardous working environments, the need to balance productivity with employee safety is the greatest challenge and, as should always be the case, safety of the workforce takes precedence.

However, it’s also the case that some of the equipment and protective gear needed to ensure maximum safety, can render operational effectiveness almost impossible.

Mining safety is a complex issue. Ventilation is a crucial part of all underground mining operations; it helps to take in fresh, cool air to the work environment and to remove stale, affected air from it – this includes small dust particles that could damage equipment and operatives.

Without the right ventilation solutions, operational activity could suffer, machinery could be damaged and operatives could be exposed to dangerous hazards.

Ventilation is required to dilute and remove hazardous substances, control the temperature and provide oxygen. But, in the event your current ventilation network is not delivering the quality you need, what can you do to improve it?

Mining safety is a complex issue. Manned and unmanned areas of the mine need to be constantly monitored for environmental changes and potential dangers, while uncharted areas of the mine need to be mapped out and evaluated for hazards before exploration can take place.

Both fixed and wireless detection systems carry benefits, but both can bring shortfalls when used in isolation.

When it comes to finding a holistic approach to mining safety, combining fixed and portable and wireless systems is always the best answer to providing a comprehensive level of security to operatives on the ground.

Glyn Jones, CEO of Trolex Group, discusses the benefits of having a diverse array of gas detection solutions to promote the most efficient, safe, mining operations possible.

We are delighted to announce that we have been nominated at this year’s Hazardex 2018 Awards for Excellence, one of the premier award evenings for suppliers of products, services and systems for use within hazardous areas.

It means we will be among four other companies vying for the title of Best User Application with our TX3706 Falcon 25 Ex Connector in a competitive category for application which highlight the benefits of a product, system or service for use in hazardous areas.

The mining and industrial workplace has continued to undergo a transformation during the last 12 months as technology plays an ever more crucial role both in employee safety, and boosting production and workflow.

Heading into 2018, there are a number of key areas which bosses and workforces should be looking at and here, Glyn Jones, CEO of Trolex Group, looks ahead to identify what will be the biggest changes and what new technology will have the biggest impact on the mining sector in the new year.

In an increasingly litigious world, protecting your business against prosecution is an essential part of any major business strategy or policy. Why then, when we have the technology available, do organisations that have employees working in hazardous environments still rely on out-dated dust monitoring systems?

Regulations are becoming tighter but with no accurate, immediate and continuous information about the current levels of dust in the environment, organisations simply cannot make employee safety and wellbeing decisions in real-time. The strategy is either based on ‘after the fact’ data or visual assessments of dust levels, and then just hope for the best. These processes are simply not good enough any longer.

There is an invisible killer affecting the UK workforce that kills over 4,000 people in the UK every year.^[1] The name of this killer - Respirable Dust. Hundreds of thousands of individuals in many different industries are working every day in high dust environments, and therefore are at risk of inhaling potential health damaging toxins, most notably silica. While regulation is being tightened with the aim of improving these working conditions, it is the fear of legal claims that is now, finally, focusing the attention of managers, boards and shareholders.

Trolex/Nome will be presenting a paper on “Improving Strata Management Through The Development of Remote Reading Instrumentation Systems” and also exhibiting the Remote Reading Telltale System.

Trolex feature in this months issue of Tunnels and Tunnelling magazine. The article focuses on our new re
al-time dust monitor which is being trialled at Liverpool Street Crossrail station, where Laing O'Rourke has the contract for the main construction work.