Reactore
•
August 11, 2025
Faster Reporting
Reduction in Unauthorised Fuel Losses
Fewer Safety Incidents
Fleet Type
Heavy-duty Haul Trucks
No. of Vehicles
12
Key Integrations
Telematics, Fuel Level Sensor
Fleet Challenges
Fuel Pilferage
Lack of Visibility
Unsafe Driving
Delayed Reporting
Key Business Impact
67% faster reporting
90% reduction in unauthorised fuel losses
40% fewer safety incidents
Solution
MineOne™ Fleet Management System
• Fuel costs are increased by unmonitored consumption.
• Trucks lack continuous, real-time location tracking.
• Safety incidents from over speeding and harsh braking are rising.
• Manual data collection delays decision-making.
• Compliance reporting and audit trails are burdensome.
The end client is a diversified construction and infrastructure group with a significant presence in South Asia. With operations spanning civil construction, hydropower, highway infrastructure, and heavy logistics, the group plays a pivotal role in driving national development projects and large=scale industrial works.
Operating a fleet of heavy-duty trucks and specialised equipment across cross-border routes, the group is known for its emphasis on operational efficiency, compliance, and safety. Their commitment to digital transformation has positioned them as an early adopter of innovative technologies to optimise project execution, logistics, and resource utilisation.
Note: Client name has been anonymised in accordance with confidentiality agreements
End-users faced five critical operational gaps:
1
Unauthorised fuel withdrawals go undetected, thus inflating costs.
2
Lack of real-time location tracking causes suboptimal asset use and productivity losses.
3
Unsafe driving behaviours (speeding, harsh braking) remain unrecorded, leading to safety incidents.
4
Manual data downloads and spreadsheet consolidation delay decision-making and extend reporting time.
5
Inconsistent sensor calibration yields unreliable readings and erodes confidence in analytics.
Reactore deployed its flagship MineOne™ Fleet Management Solution to unify vehicle telemetry, fuel sensing and analytics into a single modular platform. Leveraging an API-driven architecture and cloud-native services, MineOne™ FMS delivered real-time visibility, alerts and insights across every haul cycle that were customised to the client’s operational requirements.
Integrated Modules Implemented:
Continuous GPS monitoring, geofencing alerts and utilisation heat maps.
Live fuel-level sensing, configurable pilferage thresholds and instant notifications.
Over speeding, harsh braking and idling detection with driver scorecards.
Automated five-second data polling, local storage for up to one hour during network outages.
Industry-standard sensor calibration workflows and periodic validation checks.
Live operations dashboards, scheduled PDF reports and customised KPI widgets.
Usage-based maintenance alerts, trend analysis and downtime forecasting.
On-site deployment workshops followed by a three-month hyper care support phase.
Unmonitored Fuel Consumption
Integrated Fuel-level Sensor with Real-time Alerts
Reduced Fuel Pilferage, Improved Consumption Accountability
Inadequate Fleet Visibility
GPS-enabled Telematics Units on All Mining Vehicles
Full Asset Tracking, Optimised Fleet Deployment
Unsafe Driver Behaviour
CAN-bus Integration for Driving Pattern Analytics
Safer Operations, Increased Operator Accountability
Manual and Delayed Data Reporting
Automated Data Capture at 5-second Intervals
Faster Decision-making, 67% Reduction in Reporting Time
Inaccurate Sensor Readings
Industry-standard Calibration by Certified Partners
Reliable Data, Improved Trust in Analytics
Reactive Maintenance Practices
Predictive Maintenance Enabled via Usage Monitoring
Reduced Downtime, Extended Equipment Life
Disconnected Operational Insights
Custom Dashboards and Automated Report Generation
Streamlined Planning, Real-time Operational Oversight
Limited Field Training During Rollout
On-site Training with 3-month Hypercare Support
Faster User Adoption, Smoother Transition to Digital Operations
Data Loss in Low Connectivity Zones
Offline Buffering with Automatic Syncing
Uninterrupted Monitoring, Complete Data Continuity
To execute the implementation of the MineOne™ Fleet Management System effectively, we embraced a comprehensive process consisting of web app development, mobile app development, testing, and deployment.
Surveyed network coverage and installed GPS units, fuel-level sensors, and CAN-bus interfaces on each truck across the fleet
Tailored fuel alert thresholds, behavioural flags, and reporting templates to match the client’s operational workflows
Carried out industry-standard calibration for all fuel sensors and validated CAN-bus data mapping for reliable insights
Deployed real-time dashboards, pilferage alerting, and trip tracking views with automated reporting for key stakeholders
Conducted one week of on-site training sessions for fleet managers, drivers, and operational staff
Provided three months of hyper care support to fine-tune sync intervals, alert sensitivity, and overall system performance
Configured the telematics devices to store up to one hour of offline data during GSM outages, ensuring uninterrupted data continuity
Quantitative Improvements
Unauthorised Fuel Loss Controlled
Fuel sensors with real-time monitoring and alerts enabled the team to detect and respond to pilferage instantly, bringing unauthorised fuel loss down from 5–10% to under 1
Reporting Turnaround Time Improved
Manual reporting delays were eliminated with automated daily dashboards, allowing operational teams to access updated insights without waiting for compiled reports.
Driving-related Safety Events Reduced
By capturing CAN-bus data and analysing driver behaviour, the system helped reduce safety incidents attributed to speeding and harsh braking from 40% to 24%.
Qualitative Benefits
Offline Data Buffering
Telematics devices were configured to store up to one hour of offline data, preventing information loss during GSM outages.
Accurate Fuel Accounting
Calibrated fuel sensors and real-time alerts reduced pilferage and improved consumption tracking, optimising fuel-related expenditure.
Driver Behaviour Monitoring
CAN-bus integration enabled proactive alerts for speeding and harsh braking, promoting safer driving across the fleet.
Live Operational Dashboards
Automated dashboards with five-second data updates allowed supervisors to make route and resource decisions on the fly.
Reliable Real-time Visibility
Continuous monitoring of fuel levels, GPS movement, and distance travelled enabled full operational visibility and faster issue resolution.
*Benefits and performance improvements are based on observed operational outcomes and internal benchmarks during and after deployment. Results may vary depending on site conditions and implementation scope.
Live GPS tracking and trip-level monitoring enabled complete operational transparency across the mining fleet.
Calibrated fuel-level sensors and alert mechanisms helped identify and prevent unauthorised withdrawals in real time.
CAN-bus integration provided insights into over speeding, harsh braking, and idling, improving safety and compliance.
Telematics hardware with local data buffering ensured uninterrupted monitoring during GSM network outages.
The system was configured to match site-specific needs, with on-site training and extended hyper care ensuring smooth rollout.
Standardised calibration and validated data mappings ensured high-integrity analytics and reporting.
Explore how MineOne 360 can unify your value chain — from pit to port — with real-time insights, modular flexibility, and enterprise-grade scalability. Learn More
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