Digital efficiency: how advanced analytics increase mining productivity

First published by International Mining Engineer, May 2025

One of the most important, but often overlooked, developments in engine technology in recent decades is the dawn of digital connectivity. Whether it’s in cars, buses, or even large haul trucks, operators can take immediate access to performance data for granted. 

Cummins has over 100 years’ manufacturing engines for a range of sectors and has been at the forefront of incorporating remote analytics capabilities. Over this time, Cummins has found that whilst some sectors have been quick to embrace digitalization, others have lagged.

With the high cost of mining equipment and the critical impacts of downtime, the mining industry has the most to gain through the most advanced analytics. To maximize these potential advantages, professionals across the sector need to understand how they can best utilize modern, advanced analytics technology. 

The fundamentals – what are digital solutions?

Starting from the basics, connected diagnostic systems are technologies often incorporated with an engine to gather performance data. This collected information on engine outputs can then be remotely shared with engine manufacturers, original equipment manufacturers (OEMs) and mining engineers and operators, and assessed to inform changes to operations.

What these changes are depends on what information is shared. This can range from implementing additional training for operators on how to best use equipment, to taking machinery out of use for servicing if there are early signs of a potentially costly fault.

State of play in mining

Whilst a lot of engines in mining today are equipped with connected diagnostics systems, many operators still rely on outdated IoT systems that offer limited insight into efficiency or early warning signs of failure. Without access to real-time data, minor issues can go unnoticed until they escalate. In mining, where engines are large both in size and cost, this lack of visibility can have critical consequences.

What are the benefits today? – Mining smarter with Advanced Prognostics

Cummins’ PrevenTech® captures proprietary datasets, only interpretable by Cummins, to provide detailed breakdowns of in-service equipment health. This function enables precise, proactive intervention, that maximizes uptime and cuts down on expensive breakdown costs.

Through the latest technology advancements, Cummins is enhancing the accuracy and interpretation of its collected information. Machine learning capabilities allow Cummins systems to learn quicker, assessing large live data sets to share dynamic information and inform operations. These innovations ensure equipped applications can operate at peak performance, paving the way for a more intelligent, efficient, and sustainable mining industry. 

The proof

A benefit of connected diagnostics is that you can easily see when and where they are working. Cummins PrevenTech® equipped engines are in operation across many mining sites around the world, with mining engineers reporting real-life efficiency savings every day.

For example, in a case study of 50 equipped engines in a mining truck fleet operating over rough, mountainous terrain, Cummins PrevenTech® was used to assess an issue regarding variable speed inefficiencies.

The technology analyzed over 80 million records, with 200 plus variables, to identify correlated components and systems that were responsible for causing speed discrepancies. Through this assessment, a new targeted maintenance plan was implemented across the fleet, increasing average truck speed by 3%.

The result of this gain was a 2% improvement in annual production per truck, leading to an $800,000 increase in productivity per truck, amounting to an overall $40m annual productivity increase across the full fleet.

In another example, a large operator was frustrated by an inability to measure the usable life of filters and oil across a fleet of over 100 trucks, each hauling 320-ton loads in extreme operating conditions. To address the problem, Cummins PrevenTech® learning models, integrated with Fleetguard FIT, assessed real-time and historical data, captured from advanced sensors in oil and filtration systems, to generate early servicing alerts where needed.

As a result, service intervals across the fleet went from 42 to 50 days, with shortened inspection times due to remote diagnostics, extending engine life due to limited progressive damage.

The future

The benefits of productivity, servicing and efficiency improvements from connected diagnostic systems are clear. Products like Cummins PrevenTech® can, and have, made mining sites around the world more productive, safer and more profitable with digital integration. Moving forward, as more engines utilize these advanced monitoring systems, the analytical capabilities and what we can achieve with this information will only become greater.

As mines around the world look towards an energy transition, real-time monitoring of fuel usage and performance of power solutions will be increasingly important. By being more connected in this changing landscape, we can make more informed decisions, ensuring that the mining industry as a whole can strike a critical balance of TCO and profitability whilst achieving decarbonisation strategies.