The mining and metals industry operates in one of the most demanding environments — where extreme conditions, heavy machinery, and remote operations make maintenance reliability critical to productivity and worker safety. Equipment downtime or unscheduled repairs can quickly lead to production losses, safety risks, and supply chain delays.
PlantOps360 delivers a powerful, IoT-enabled maintenance and asset management platform that helps mining and metallurgical plants maximize uptime, optimize asset utilization, and ensure compliance with strict safety and environmental standards.
Whether managing crushers, conveyors, smelters, haul trucks, or mill equipment, PlantOps360 enables your teams to monitor, maintain, and analyze every asset across open-pit and underground operations — all from a single, unified dashboard.
Industry Challenges in Mining & Metals Maintenance
The complexity of mining operations introduces unique maintenance challenges that traditional systems fail to address.
Common issues include:
Remote site operations
Remote site operations with limited connectivity and delayed data updates.
Unplanned breakdowns
Unplanned breakdowns of high-value equipment like draglines, crushers, and trucks.
Reactive maintenance culture
Reactive maintenance culture due to lack of predictive visibility.
Safety compliance gaps
Safety compliance gaps in hazardous working environments.
High cost of spare part logistics
High cost of spare part logistics across distributed mine sites.
Limited visibility
Limited visibility into equipment performance and lifecycle costs.
PlantOps360 solves these pain points with a mobile-first, offline-capable, and IoT-integrated maintenance system — enabling mining teams to shift from firefighting to foresight.
How PlantOps360 Transforms Mining & Metals Operations
PlantOps360 delivers an integrated digital ecosystem that optimises mining and metals operations through real-time visibility, predictive maintenance, and data-driven decision-making — enhancing productivity, safety, and operational efficiency across every site.
Integrate vibration, pressure, and oil analysis sensors with PlantOps360 to monitor critical equipment like mills, crushers, and conveyors. AI algorithms detect anomalies and trigger predictive maintenance tasks before failures occur.
Outcome: 30–40% reduction in unplanned downtime and improved asset life cycle management.
Technicians can access and update work orders via the PlantOps360 mobile app even in offline mode. Once connected, data automatically syncs with the central dashboard.
Outcome: Seamless maintenance reporting and reduced manual data errors in low-connectivity environments.
From mine sites to processing plants, all equipment data — maintenance logs, runtime hours, sensor data — is centralized for decision-making.
Outcome: Standardized maintenance practices across geographically dispersed operations.
Digitally track equipment inspections, PPE checks, and environmental compliance documentation. Assign safety tasks and incident reports directly to responsible teams.
Outcome: 100% compliance visibility and reduced EHS risks.
PlantOps360 integrates with SAP PM, Oracle EAM, and SCADA systems for seamless data exchange — ensuring that maintenance costs, production schedules, and asset downtime are aligned.
Outcome: Improved coordination between operations, maintenance, and finance departments.
Key Use Cases in Mining & Metals Industry
Predictive Maintenance for Crushing Equipment
IoT vibration and temperature sensors monitor crushers for bearing wear and overload conditions. Predictive alerts trigger maintenance actions before breakdowns occur.
Result: 35% increase in crusher availability and fewer emergency shutdowns.
Fleet Maintenance Management
Track maintenance schedules, fuel usage, and part replacements for haul trucks, loaders, and bulldozers.
Result: 20% lower fuel consumption and optimized equipment utilization across the fleet.
Conveyor Belt Condition Monitoring
Real-time torque and temperature monitoring of conveyor drives help detect misalignments and prevent belt tears.
Result: 25% reduction in maintenance costs and increased belt life.
Smelter Equipment Maintenance
Plan and execute maintenance schedules for furnaces, scrubbers, and cooling systems based on runtime data from PLCs and sensors.
Result: Improved process stability and reduced maintenance-induced downtime.
Remote Mine Site Maintenance via Mobile App
Technicians working in remote mining regions use Zebra handhelds to capture task updates, upload equipment photos, and scan barcodes for spare parts issuance.
Result: Real-time asset traceability and 100% field visibility.
Core Benefits for Mining & Metals Operations
- 40% Downtime Reduction through IoT-based predictive maintenance.
- Increased Asset Reliability with automated work order scheduling and condition monitoring.
- Improved Safety & Compliance via digital inspection workflows and EHS documentation.
- Enhanced Productivity with mobile, offline-enabled maintenance.
- Lower Operational Costs through optimized spare parts management and vendor control.
- Real-Time Decision Support powered by analytics dashboards and Power BI integration.
Integration & Automation Ecosystem
Mining and metals operations rely on interoperability between multiple systems. PlantOps360 integrates effortlessly with your existing enterprise and plant systems to create a connected, automated ecosystem.
Supported Integrations:
- ERP: SAP PM, Oracle EAM, Microsoft Dynamics 365
- IoT & Condition Monitoring: MQTT, Modbus, OPC-UA, Rockwell, Emerson
- SCADA/PLC Systems: Siemens TIA Portal, Schneider Electric, ABB
- Barcode & RFID: Zebra, Honeywell, SATO
- Analytics & Visualization: Power BI, Tableau, Qlik
- Cloud Platforms: AWS IoT Core, Azure IoT Hub
Outcome: Unified visibility from equipment sensor data to enterprise-level financial insights — enabling predictive decision-making and continuous process improvement.
FAQs for Mining & Metals Industry
Yes. The mobile app offers full offline functionality, allowing technicians to log work orders and inspections without connectivity. Data syncs automatically once reconnected.
Through IoT sensor integration and machine learning algorithms that monitor vibration, oil quality, and runtime data to predict failures before they occur.
Absolutely. It provides pre-built connectors for SAP, Oracle, Microsoft Dynamics, and SCADA platforms to ensure seamless data exchange.
PlantOps360 digitizes safety inspections, environmental logs, and PPE checks, ensuring all activities are recorded with timestamps and digital sign-offs.
Yes. The system tracks both stationary and mobile assets — such as trucks, loaders, and excavators — using barcode or RFID scanning.
Talk to a PlantOps360 Specialist
Achieve operational resilience and safety excellence across your mining and metals operations with IoT-powered predictive maintenance and unified visibility.
