Bharat Bauxite-Case Study
Olivia Rhye
•
20 Jan 2022
About the Client
Bharat Bauxite, a leading bauxite mining and aluminium production company in India, is known for innovation, sustainability, and excellence. With vast mining operations and advanced refining capabilities, it supplies high-quality products to industries like automotive, construction, and consumer goods. Committed to eco-friendly practices and community engagement, it sets benchmarks in sustainable mining
*All names and logos have been changed to respect the NDA.
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
30%
Improvement in fleet and haulage efficiency
30%
Improvement in fleet and haulage efficiency
Business Requirements/Problem Statement
Bharat Bauxite’s existing mining operations suffer from fragmented data flows due to isolated systems and manual processes. Critical operational metrics, including real-time production status, grade reconciliation, and material movement, are dispersed across various digital tools and legacy systems, hindering the extraction of actionable KPIs. This disjointed approach not only limits operational transparency and efficiency but also results in data inconsistencies and excessive manual intervention. Their business required a robust system that leverages advanced integration techniques, including API connectivity and IoT sensor data aggregation, to centralise data from diverse sources such as PLCs (Programmable Logic Controllers) and DCSs (Distributed Control Systems) systems, fleet monitoring system, drone surveys, and land management platforms.
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
Enhanced Decision-Making through Real-Time Insights
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Enhanced Decision-Making through Real-Time Insights
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Suspendisse varius enim in eros elementum tristique. Duis cursus, mi quis viverra ornare, eros dolor interdum nulla, ut commodo diam libero vitae erat. Aenean faucibus nibh et justo cursus id rutrum lorem imperdiet. Nunc ut sem vitae risus tristique posuere.
Enhanced Decision-Making through Real-Time Insights
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Suspendisse varius enim in eros elementum tristique. Duis cursus, mi quis viverra ornare, eros dolor interdum nulla, ut commodo diam libero vitae erat. Aenean faucibus nibh et justo cursus id rutrum lorem imperdiet. Nunc ut sem vitae risus tristique posuere.Lorem ipsum dolor sit amet, consectetur adipiscing elit. Suspendisse varius enim in eros elementum tristique. Duis cursus, mi quis viverra ornare, eros dolor interdum nulla, ut commodo diam libero vitae erat. Aenean faucibus nibh et justo cursus id rutrum lorem imperdiet. Nunc ut sem vitae risus tristique posuere.
Enhanced Decision-Making through Real-Time Insights
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Suspendisse varius enim in eros elementum tristique. Duis cursus, mi quis viverra ornare, eros dolor interdum nulla, ut commodo diam libero vitae erat. Aenean faucibus nibh et justo cursus id rutrum lorem imperdiet. Nunc ut sem vitae risus tristique posuere.
Enhanced Decision-Making through Real-Time Insights
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Suspendisse varius enim in eros elementum tristique. Duis cursus, mi quis viverra ornare, eros dolor interdum nulla, ut commodo diam libero vitae erat. Aenean faucibus nibh et justo cursus id rutrum lorem imperdiet. Nunc ut sem vitae risus tristique posuere.
Enhanced Decision-Making through Real-Time Insights
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Suspendisse varius enim in eros elementum tristique. Duis cursus, mi quis viverra ornare, eros dolor interdum nulla, ut commodo diam libero vitae erat. Aenean faucibus nibh et justo cursus id rutrum lorem imperdiet. Nunc ut sem vitae risus tristique posuere.
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.
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.
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.
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.
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.
Project Results
Through automation, AI, and real-time data integration, Reactore delivered:
25%
Reduction in material losses through real-time stockpile monitoring
25%
Reduction in material losses through real-time stockpile monitoring
25%
Reduction in material losses through real-time stockpile monitoring
25%
Reduction in material losses through real-time stockpile monitoring
25%
Reduction in material losses through real-time stockpile monitoring
25%
Reduction in material losses through real-time stockpile monitoring
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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