Case Study
A multi-shaft mining operation automated 150–300 daily reports with zero manual intervention.
Mining operations generate thousands of data points every shift across multiple shafts, processing plants, and surface facilities. i-Con connected every data source and turned what had been hours of manual reporting into a fully automated document factory running in real time, every shift, every day.
120K+
Records per automated run
Demonstrated in production environments, processing SCADA, LIMS, ERP, weigh bridge, and personnel data in a single automated cycle.
<1 sec
Per document generated
Full cycle data collection, document generation, PDF conversion, encryption, and email distribution completed in under one second per document.
300/day
Documents automated daily
Across a 4-shaft operation: 50–100 documents per shift, 3 shifts per day. All generated, encrypted, and distributed without manual action.
Zero
Manual interventions required
Shift handovers, regulatory submissions, contractor statements, and blast clearance packs all generated and distributed automatically.
Overview
Overview
Without automation, an outgoing shift supervisor typically spends 30–45 minutes manually compiling a handover report pulling figures from SCADA dashboards, LIMS printouts, weigh bridge logs, and ERP exports. Across a multi-shaft operation with three shifts per day, this equates to hundreds of person-hours per month dedicated to data collation rather than operational management.
Multiple heterogeneous data sources SCADA, LIMS, weigh bridge, ERP, personnel tracking with no common integration layer.
Shift reports compiled manually by supervisors, introducing delay, inconsistency, and human error.
Regulatory submissions for DMRE required month-end data gathering across 30 days of shift records a multi-day exercise.
Template changes for reports required developer involvement, adding cost and delay.
200+ contractors on site generating individual monthly compliance statements all produced manually.
i-Con Capability Overview
i-Con Capability Overview
i-Con connects simultaneously to all data sources across the mine environment. At shift-end, a single workflow trigger causes i-Con to query every connected system, validate and normalise the data, populate report templates with conditional formatting, convert documents to encrypted PDF, and distribute them to the correct recipients all in under one second per document.
SCADA / PLC Systems
Real-time equipment performance: conveyor throughput, pump pressures, ventilation fan speeds, hoisting cycles.
LIMS
Ore grade assay results per shift, per blast block, per stockpile pulled directly into grade reports and mine planner packs.
Weigh Bridge Systems
Tonnes hauled per truck, per shift, per pit section automatically included in production summaries.
ERP Platforms
Maintenance work orders, cost centre data, consumables usage feeding into management reports and contractor charge-backs.
Automated Document Outputs
Automated Document Outputs
| Document | Frequency | Recipients |
|---|---|---|
| Shift Production Report | 3× daily per shaft | Mine Overseer, Production Manager |
| Equipment Availability Report | 3× daily per section | Engineering Superintendent |
| Safety Observation Summary | 3× daily per section | Safety Officer, Section HOD |
| Ore Grade Report (from LIMS) | 3× daily per stream | Metallurgist, Mine Planner |
| Headcount & Personnel Report | 3× daily per shaft | HR, Emergency Response Officer |
| Shift Handover Pack | At each shift-end | Incoming Shift Supervisor |
| Monthly DMRE Regulatory Submission | Monthly | Dept of Mineral Resources & Energy |
| Contractor Hours & Compliance Statements | Monthly per contractor | Contractors, Finance, HR |
| Blast Clearance Documentation | Event-triggered | Blasting Officer, Safety, Engineering |
| Environmental Monitoring Report | Continuous / Monthly | Environmental Manager, Regulator |
High-volume reporting still done manually?
Talk to the Prosol team about how i-Con can automate your document production and data integration workflows.