FROM ROAD BOTTLENECKS TO OPTIMISED FLOWS: CYCLE TIMES REDUCED

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1. DATA INSIGHTS UNCOVER ROAD CHALLENGES

Our client had opted for SmartFleet^DX LIVE to support the monitoring of their operations. During a haul road performance analysis, the SmartFleet^DX remote monitoring team identified inefficiencies in segments Sections 01–14.

The review of loaded and empty truck speeds revealed:

• Declining speeds in later segments (Sections 12–14)
• Low truck speeds in early loading segments (Sections 01–04)
• High variability and congestion in mid-sections (Sections 08–10)

These patterns indicated that surface conditions, traffic flow and operational practices were extending cycle times and limiting throughput.

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2. ACTIONS IMPLEMENTED

Based on these insights, the client took targeted actions:

• Road maintenance and upgrades, including grading, surfacing and dust control, particularly in Sections 05–14.
• Traffic optimisation, including improved routing, shift scheduling and congestion management in the middle sections.
• Equipment and operator enhancements, including truck servicing for inclines and operator coaching for consistent speed control.

These measures aimed to stabilise speeds, reduce variability, and shorten cycle times without compromising safety.

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3. TARGETED ACTIONS DRIVE IMPROVEMENTS

By May, the impact of these interventions could be seen in the updated haul road metrics:

• Speed increases: peak speeds rose into the high 30s km/h, with higher medians and improved consistency.
• Cycle time reduction: average cycle times dropped by 8.8%, mainly due to faster empty returns.
• Load growth: loads increased by 29.2%, exceeding gains from cycle time alone and pointing to improved scheduling efficiency.

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April key metrics:

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May key metrics:

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4. PRODUCTIVITY IMPACT

The combined effect of shorter cycles and more efficient scheduling was an increase of around 25% in daily loads (assuming similar days).
This directly translated into a higher capacity for material movement and revenue potential.

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5. END RESULT: DATA-DRIVEN DECISION-MAKING DELIVERS

This case study demonstrates how SmartFleet^DX LIVE transformed April's diagnostic insights into operational improvements by May.
Targeted interventions in road conditions, traffic flow and equipment practices improved speed, cycle times and load capacity, setting a new standard for continuous improvement in mining operations.