Key takeaways:
Each year, between 30-40% of mining industry deaths are attributable to failures of vehicle interaction controls, according to research from the Earth Moving Equipment Safety Round Table. Of these deaths, about half involve pedestrians.
With data integrated from sensors and cameras, a Collision Avoidance System (CAS) helps detect potential hazards and alerts the operator to take action. By enhancing the situational awareness of machine operators, and everyone else working at the mine, a CAS can significantly mitigate the risk of collision accidents.
Implementing a Collision Avoidance System is not an overnight process. But like any challenge, if you break it up into small pieces, achieving your goal is easier.
CAS implementation requires a multi-layered approach that includes factors such as site design, evaluation of operating procedures, risk assessment and staff training. The CAS is like the goalkeeper in football — they're the last line of defence, but you need the entire team to play their roles effectively in front of that goalie.
To help you support greater safety in your mine, here’s an overview of the Collision Avoidance System integration process.
The Earth Moving Equipment Safety Round Table (EMESRT) has developed a framework mapping nine levels of control for mine vehicles. The first level starts with site design. It’s a crucial place to start, but while you can design a mine to be safe, it’s nearly impossible to cover every possible scenario.
You can then add segregation control, operating procedures, training, and authority to operate. Each layer adds on more safety, but at some point, these things are just not enough.
If you look at the right-hand column of the chart below, the reaction time of designing a mine takes years. Doing a pre-shift inspection, the interval of detecting safety issues is in the order of just hours, but there are still risks that remain. Where Level 6 safety interventions reaction times are not enough, you will need to implement Level 7 to Level 9 depending on the identified risks.
EMESRT defines three layers of safety for a CAS. Level 7 is where alerts from the CAS make the operator aware of people or threats near the machine. Level 8 takes it one step further and the system now advises the operator to slow down or stop with voice and other indication alerts.
If an operator does not heed to the advice from the CAS, the machine will then automatically go to Level 9, where it intervenes. The CAS will first slow down the machine, and then if needed, it will stop the machine.
This is a complex world to live in, because in a mine, you don't have just one type of machine. You have machines from different vendors and OEMs, but they all need to be controlled with one system.
So, you have a system engineering challenge. But that’s a challenge that can be solved with time and support from an experienced partner who can deliver a CAS solution that suits your needs today, and helps you plan with the future in mind.
Technology is always the easy part of digital transformation. It's complicated — but it's the easy part. People are the hard part.
Successful digitalization requires a comprehensive strategy that includes change management, cultural shifts, and workforce skill development. The synchronization of people, processes, and technology is integral to automation and information management strategies, particularly in underground mining operations.
Resistance to change is near the top of the list of potential challenges of digitalization. Seasoned operators who are used to driving by the seat of their pants may be especially resistant to new technologies that disrupt their well-established workflow.
That’s why it’s essential to involve staff in the process from the outset and to provide adequate training as part of your change management strategy. While training is essential, you'll also need to emphasize the value the CAS provides in terms of safety for everyone in the mine. Without that understanding of the critical value of CAS, it might be difficult for operators to adapt.
Following the ADKAR framework, staff should be made aware of the risks and have a desire to address them. To ensure the new processes and technologies deliver the desired results, leaders must consistently address resistance to change, foster open communication, and provide adequate support and training for employees.
Before implementing a CAS, you should define clear objectives. What’s your desired outcome? Compliance, enhanced safety standards, better efficiency, or all of the above?
With your broad objectives defined, you can set more specific goals, such as reducing collisions between specific vehicle types, or protecting pedestrians in designated areas. Additionally, you’ll want to consider the scalability of the solution to accommodate future expansions or changes in your setup.
EMESRT has developed a framework to identify areas with high collision risks at your site, considering factors such as vehicle types, traffic patterns, and blind spots. With this framework, you can assess your site and better understand what your CAS vendor needs to deliver.
Once you have a firm grasp on your risks and goals, you can begin to evaluate vendor solutions. You're making a significant long-term investment here, so you need to get this right. Look for reputable vendors with extensive experience in the mining industry and a proven track record of delivering reliable solutions.
The Mining Industry Occupational Safety and Health (MOSH) organization have established specifications to help you to properly evaluate a system’s real-world performance. Work closely with your prospective vendors, putting their solutions through the paces with MOSH's testing criteria.
There is a risk that a vendor may lock you into a siloed system that’s hard to break out of. Most miners have a mixed fleet of machines from various OEMs, so it’s important to evaluate your integration possibilities to ensure that your entire fleet can be integrated with the CAS solution.
Working with vendors that offer OEM agnostic solutions will provide you with more flexibility as you scale up in the future. You should also consider how your vendor adheres to industry standards, such as the ISO 21815 digital CAN bus interface, which facilitate integration and data logging for incident investigations, should an accident occur.
If your organization lacks in-house skills such as design thinking, systems thinking, and change management, a CAS vendor that can also offer support in those areas can be a huge benefit.
Integrating new technologies with existing systems can be complex and challenging. To make it easier, it’s important to have a well-defined integration roadmap and to conduct thorough testing before fully deploying any new technologies.
You’ll need to develop a comprehensive implementation plan that outlines the timeline, process and responsibilities for each stakeholder involved. To ensure a smooth transition, plot out potential challenges and plan for contingencies.
In the digital age, you’re mining data. To get the full value of digitalization, you need everything to work together seamlessly. Again, this is where the interoperability of your vendor’s solution is essential.
Integrating the CAS with your existing operational systems and machinery should ensure seamless communication and data exchange. To achieve this, conduct thorough testing under various operational conditions to validate the system's accuracy and reliability in detecting and preventing collisions.
Collaborate with OEMs and CAS vendors to ensure proper integration, and to address any potential warranty or liability concerns. To facilitate root cause analysis and continuous improvement, establish clear protocols for data logging and incident investigation.
Safety is non-negotiable in the mining industry. To support miners with all aspects of safety and situational awareness, Epiroc has invested in expanding both our solution portfolio and our in-house expertise in recent years. That includes industry-leading, OEM-agnostic Collision Avoidance Systems.
Your mine is equipped with a mixed fleet of makes and models, and your CAS and safety solutions should accommodate that. We offer proven CAS solutions not limited to Epiroc-branded equipment to enhance your operation's safety and productivity.
Epiroc partners with mining companies to support successful digital transformations. Wherever you are on your transformation journey, we provide scalable solutions that align with your operation and your goals - for your machine, fleet or your entire mine.
