By Neville Judd
Long hours, repetitive tasks and heavy machinery are the norm in mining: so, too, are fatigue and distraction. Tackling both is not just important, it’s essential for ensuring safety and productivity.
Fatigue is a silent threat lurking in workplaces across the globe, contributing to at least 20% of all workplace incidents and costing employers $135 billion annually, according to the National Institute for Occupational Safety and Health (NIOSH).
Given the complexities of mining underground, it’s certainly plausible that the risks posed by fatigue and distraction are even greater. As mines push deeper beneath the surface for deposits, the need for better communication and collaboration increases.
MMG, a globally recognized producer of base metals, is familiar with these realities. Operating in diverse and challenging environments, MMG is committed to protecting its workforce and ensuring that every employee returns home safely.
A new video explains how MMG partners with Hexagon to address the critical safety challenge of operator fatigue at the Rosebery mine in Tasmania.
How OAS enhances operator safety at Rosebery mine
The underground environment at Rosebery intensifies the risks associated with operator alertness. Acknowledging that fatigue and distraction could compromise safety, MMG sought innovative solutions to mitigate these hazards. Enter Hexagon’s Operator Alertness System (OAS), a solution designed to enhance operator safety.
“The Hexagon OAS system has been so good for us,” said Wendy Hodgetts, Manager-Safety, Training, Health, ER & Security, MMG Rosebery. “It was really valuable in the early stages to bring an operator in, show them the system, show them what it actually looked like for them on the screen so they could view themselves and a lot of them actually realized that they weren’t aware of their own fatigue.”
“Our truck drivers are driving at very low speeds, loaded, up a decline and it gets very monotonous for the work they do.”
Hexagon’s OAS employs advanced sensor technology and machine-learning algorithms to monitor operators’ alertness levels actively. When signs of distraction, drowsiness, or microsleeps are detected, operators receive real-time notifications, providing a crucial layer of protection during their demanding 12-hour shifts.
“I have been fatigued a fair few times, especially on night shift,” said Matthew Puckridge Truck Operator, MMG Rosebery. “It [OAS] works really well, it’s loud, it wakes you up if you do doze off, and the seat vibrates … I love the system. It works well.
“I’ve got a wife and five kids at home, and I want to go home to them every single night and enjoy my family time.”
Hodgetts added that open communication with Hexagon has been invaluable to the success of OAS.
“I think there’s some real advantages with the relationship we’ve had with Hexagon, it’s been very open, and I think early support was critical to the successful implementation of this engineering control into our workforce and into our trucks.
“Hexagon said ‘You won’t need many spares. We don’t have a lot of equipment failures’. So, we trusted Hexagon, and of course, we’ve held one spare unit on our shelf for nearly three years now since we’ve had this in operation, and we’ve replaced one camera.”
The deployment of OAS on Rosebery’s underground haulage fleet has marked a significant advancement in MMG’s safety initiatives. The system’s adaptability to the mine’s challenging environment and the emphasis on change management ensured its successful integration.
By fostering a culture of safety, MMG and Hexagon demonstrated that credible safety enhancements must be backed by proven methodologies to achieve lasting impact.
Operators empowered by real-time alerts for fatigue, distraction
The results at Rosebery have been transformative. Real-time alerts for fatigue and distraction have empowered operators to respond proactively, significantly reducing the risk of accidents. The data generated by OAS has provided valuable insights, enabling management to continuously assess and address fatigue risks objectively and in real time.
“The deployment of Hexagon OAS is providing valuable data for our operation and making a difference in the safety of MMG’s workers,” said Steve Scott, General Manager at Rosebery, MMG. “We recognize that with long shifts, fatigue can become a hazard, and this technology enables us to continually assess and address the fatigue risk of our underground truck operators objectively, in real time.”
“Any worker that comes to work should go home safely every day. Hexagon has a system that allowed us to … deliver on that promise to our employees that we will keep them safe at all times.”
The collaboration between Hexagon and MMG exemplifies a successful partnership that prioritises safety without compromising productivity. In fact, the Australian Mining Prospect Awards recognised Hexagon for Mine Project Success of the Year, an award reserved for a singular engineering or contract mining project that has delivered measurable improvement at a mining site.
By integrating leading technology to address the challenges of fatigue and distraction, both companies have demonstrated their commitment to advancing safety standards and ensuring that everyone gets home safely. This partnership highlights the transformative potential of employing technology to revolutionise safety protocols and operational excellence in underground mining operations.
We’ll be sharing that story in more detail in a white paper to be presented at the AusIMM Underground Operators Conference 2025 (April 7-9).
MMG leading the way
Addressing fatigue in the workplace is not just a safety measure; it’s an investment in the well-being of employees and the overall success of operations. As NIOSH statistics remind us, tackling fatigue is crucial in reducing workplace incidents and safeguarding the workforce. Through innovative solutions like Hexagon’s OAS, companies like MMG are leading the way in creating safer, more productive work environments.
Throughout 2025 we’ll be blogging about the challenges facing the mining industry. Drawing upon insights from thought leaders in our customer community and from within Hexagon, we’ll share how trusted partnerships and proven technology are addressing those challenges, helping to improve safety and cut costs while balancing the demands of productivity and sustainability.