Revolutionize Workforce Management with Reactore 1
Rectore
•
April 2, 2025
About the Client
Bharat Bauxite operates with an Environmental Clearance (EC) capacity of 15 million metric tonnes across four (4) states and 27 (twenty-seven) mining leases. They commissioned Reactore to develop an integrated digitalisation solution that consolidates real-time operational data across its bauxite mine clusters spanning across two states.
Executive Summary/Project Overview
Bharat Bauxite operates with an Environmental Clearance (EC) capacity of 15 million metric tonnes across four (4) states and 27 (twenty-seven) mining leases. They commissioned Reactore to develop an integrated digitalisation solution that consolidates real-time operational data across its bauxite mine clusters spanning across two states. The project aimed to unify diverse data sources – from extraction and processing to transportation and blending – into a single system with multi-tier dashboards, thus enabling stakeholders to track key performance indicators (KPIs) and make informed decisions. The primary objective was to implement an Integrated Mine Management System that centralised data from various sources, including on-site manual entries and automated systems such as weighbridges, drone surveys, and PLC-based rope conveyor systems. By providing a comprehensive real-time digitalised dashboard, the solution aimed to enhance operational visibility, optimise resource planning, and streamline production processes across the bauxite mine cluster.
30%
Improvement in fleet and haulage efficiency
25%
Reduction in material losses through real-time stockpile monitoring
20%
Cost savings in blasting operations with AI-driven optimisation
Executive Summary/Project Overview
Bharat Bauxite operates with an Environmental Clearance (EC) capacity of 15 million metric tonnes across four (4) states and 27 (twenty-seven) mining leases. They commissioned Reactore to develop an integrated digitalisation solution that consolidates real-time operational data across its bauxite mine clusters spanning across two states. The project aimed to unify diverse data sources – from extraction and processing to transportation and blending – into a single system with multi-tier dashboards, thus enabling stakeholders to track key performance indicators (KPIs) and make informed decisions. The primary objective was to implement an Integrated Mine Management System that centralised data from various sources, including on-site manual entries and automated systems such as weighbridges, drone surveys, and PLC-based rope conveyor systems. By providing a comprehensive real-time digitalised dashboard, the solution aimed to enhance operational visibility, optimise resource planning, and streamline production processes across the bauxite mine cluster.
Challenges
01
Unstructured Stockyard Management
Managing stockpiles efficiently was another challenge for Bharat Bauxite. It was difficult to maintain accurate records of bauxite reserves and ensure seamless dispatch operations. The company struggled with:
- Stockpile visibility issues – No clear record of where specific stockpiles were stored, their grade, and aging.
- Lack of automated tracking – Material movement within the stockyard was not monitored in real-time.
Geo-fencing gaps – Trucks entering and exiting the stockyard were not systematically tracked, leading to logistical inefficiencies.
02
Unstructured Stockyard Management
Managing stockpiles efficiently was another challenge for Bharat Bauxite. It was difficult to maintain accurate records of bauxite reserves and ensure seamless dispatch operations. The company struggled with:
- Stockpile visibility issues – No clear record of where specific stockpiles were stored, their grade, and aging.
- Lack of automated tracking – Material movement within the stockyard was not monitored in real-time.
Geo-fencing gaps – Trucks entering and exiting the stockyard were not systematically tracked, leading to logistical inefficiencies.
03
Unstructured Stockyard Management
Managing stockpiles efficiently was another challenge for Bharat Bauxite. It was difficult to maintain accurate records of bauxite reserves and ensure seamless dispatch operations. The company struggled with:
- Stockpile visibility issues – No clear record of where specific stockpiles were stored, their grade, and aging.
- Lack of automated tracking – Material movement within the stockyard was not monitored in real-time.
Geo-fencing gaps – Trucks entering and exiting the stockyard were not systematically tracked, leading to logistical inefficiencies.
04
Unstructured Stockyard Management
Managing stockpiles efficiently was another challenge for Bharat Bauxite. It was difficult to maintain accurate records of bauxite reserves and ensure seamless dispatch operations. The company struggled with:
- Stockpile visibility issues – No clear record of where specific stockpiles were stored, their grade, and aging.
- Lack of automated tracking – Material movement within the stockyard was not monitored in real-time.
Geo-fencing gaps – Trucks entering and exiting the stockyard were not systematically tracked, leading to logistical inefficiencies.
Solutions
01
Unstructured Stockyard Management
Managing stockpiles efficiently was another challenge for Bharat Bauxite. It was difficult to maintain accurate records of bauxite reserves and ensure seamless dispatch operations. The company struggled with:
- Stockpile visibility issues – No clear record of where specific stockpiles were stored, their grade, and aging.
- Lack of automated tracking – Material movement within the stockyard was not monitored in real-time.
Geo-fencing gaps – Trucks entering and exiting the stockyard were not systematically tracked, leading to logistical inefficiencies.
02
Unstructured Stockyard Management
Managing stockpiles efficiently was another challenge for Bharat Bauxite. It was difficult to maintain accurate records of bauxite reserves and ensure seamless dispatch operations. The company struggled with:
- Stockpile visibility issues – No clear record of where specific stockpiles were stored, their grade, and aging.
- Lack of automated tracking – Material movement within the stockyard was not monitored in real-time.
Geo-fencing gaps – Trucks entering and exiting the stockyard were not systematically tracked, leading to logistical inefficiencies.
03
Unstructured Stockyard Management
Managing stockpiles efficiently was another challenge for Bharat Bauxite. It was difficult to maintain accurate records of bauxite reserves and ensure seamless dispatch operations. The company struggled with:
- Stockpile visibility issues – No clear record of where specific stockpiles were stored, their grade, and aging.
- Lack of automated tracking – Material movement within the stockyard was not monitored in real-time.
Geo-fencing gaps – Trucks entering and exiting the stockyard were not systematically tracked, leading to logistical inefficiencies.
04
Unstructured Stockyard Management
Managing stockpiles efficiently was another challenge for Bharat Bauxite. It was difficult to maintain accurate records of bauxite reserves and ensure seamless dispatch operations. The company struggled with:
- Stockpile visibility issues – No clear record of where specific stockpiles were stored, their grade, and aging.
- Lack of automated tracking – Material movement within the stockyard was not monitored in real-time.
Geo-fencing gaps – Trucks entering and exiting the stockyard were not systematically tracked, leading to logistical inefficiencies.
How We Solved Their Business Requirements and Challenges
Addressing Operational Complexity
The mining process involves numerous interdependent stages – from extraction to dispatch. Our modular solution, which included dedicated systems for land data management, mineral reserve modelling, and dispatch monitoring, was designed to manage this complexity. By digitalising each process step, we reduced the risks of miscommunication and inefficiencies inherent in manual processes.
Contractor Payment Automation
The system automated contractor payments based on actual equipment utilisation and task completion. Payments were calculated in real-time using data from mine equipment, vehicle transport logs, and weighbridge records, eliminating disputes and ensuring fair compensation.
Digitalisation Assessment of Bharat Bauxite’s Mines
Reactore conducted a comprehensive assessment to evaluate Bharat Bauxite’s digital maturity and identify operational inefficiencies. This included workflow analysis, technology gap identification, infrastructure readiness evaluation, and standardisation of data collection. A phased digital transformation roadmap was developed to ensure a structured transition from manual to digitalised operations.
Eliminating Manual Intervention
One of the primary challenges was the reliance on manual data collection across various mining operations, which led to inefficiencies and inaccuracies. Our solution automated data capture via integrated sensors, RFID tags, and mobile applications, thereby ensuring higher data fidelity and streamlined operations.
Enhanced Decision-Making through Real-Time Insights
The digital dashboard provided a single source of truth for all key performance indicators. This centralised approach enabled better planning and more informed decision-making, particularly for blending operations and material movement tracking. The real-time updates empowered stakeholders to respond swiftly to operational challenges, such as discrepancies in material grade or quantity.
Resource Utilisation and Cost Efficiency
Real-time equipment tracking helped monitor machine downtime and maintenance needs, ensuring better asset utilisation. The system provided insights into fuel consumption, operating hours, and overall equipment efficiency.
Safety and Compliance Enhancement
A form-based safety and sustainability application was deployed to monitor safety parameters and regulatory compliance. Geo-fencing of hazardous zones prevented unauthorised access, and automated compliance reporting reduced administrative overhead.
Scalable and Future-Ready Infrastructure
The system was designed with a modular and scalable architecture, allowing Bharat Bauxite to expand its digital initiatives seamlessly. Integration with ERP, SCADA, and other enterprise solutions ensured interoperability and long-term adaptability to evolving mining technologies.
Seamless System Integration
Bharat Bauxite’s existing disparate systems were digitally bridged with the implementation of an Integrated Mine Management System (IMMS) that centralised all mining operations into a single platform. By developing APIs to integrate with existing third-party systems like the Datamine, ArcGIS, DCS/PLC, IoT, LIMS and Oracle ERP, as well as with newer technologies (e.g., drone survey data for 3D mapping), we achieved a seamless data flow. Additionally, integration with weighbridges and rope conveyors enabled real-time material reconciliation, eliminating discrepancies in stock management. This integration addressed the challenge of data silos, allowing for a holistic view of their mine operations.
Our Approach
To execute the implementation of the Mine Management and Information System effectively, we embraced a comprehensive process consisting of web app development, mobile app development, testing, and deployment.
Site Analysis
Reactore conducted an in-depth site analysis at Bharat Bauxite’s mining locations to understand existing workflows, operational bottlenecks, and technological limitations. This included studying mine layouts, stockyard configurations, transportation networks, and on-ground data collection methods. The analysis helped identify key areas where digital interventions could drive the most impact, ensuring a tailored and practical digital transformation strategy.
Technology Integration Planning
A blueprint was developed for seamless integration of existing mining applications (e.g., Datamine) with Reactore’s Integrated Mine Management System (IMMS). This ensured that all critical mining data could be accessed from a single interface for enhanced decision-making and operational transparency.
Web App Development
We created an adaptable online platform serving as the core control center for managing mines' operations. The main stages include requirement analysis, UI/UX design, database development, real-time data processing, API integration, and unit and integration testing. This resulted in a robust solution capable of delivering actionable insights promptly.
Mobile App Development
For on-field operation personnel, we crafted a mobile app offering remote mine management capabilities. It ensures cross-platform compatibility while incorporating GPS and IoT integration, offline functionality, user authentication and security features.
Testing And Deployment
Adopting a strict testing procedure ensured stability, efficiency, and safety. User acceptance testing preceded the deployment phase, followed by gradual rollouts and hands-on training programs at the site level. Continuous feedback from on-ground teams allowed for iterative improvements before a full-scale rollout, ensuring a smooth transition to digital operations. Post-deployment assistance, including continuous performance surveillance and routine upgrades, guarantees uninterrupted service delivery and seamless adaptation to evolving requirements.
Project Results
Through automation, AI, and real-time data integration, Reactore delivered:
30%
Improvement in fleet and haulage efficiency
25%
Reduction in material losses through real-time stockpile monitoring
20%
Cost savings in blasting operations with AI-driven optimisation
20%
Cost savings in blasting operations through AI-driven optimization
30%
Increase in operational efficiency using predictive AI models
15%
Reduction in environmental impact due to smart resource management
With Reactore’s innovative digital mining solutions, Bharat Bauxite now operates with higher efficiency, improved safety, and better sustainability, ensuring long-term operational excellence.
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