By Neville Judd
In an open-cut mine, every second counts. With massive machines in constant motion and crews working day and night, visibility and alertness are vital. For Whitehaven Coal, improving situational awareness across its fleet at Tarrawonga open cut mine meant finding a smarter way to connect its people, vehicles, and data.
Tarrawonga is part of the bedrock of Whitehaven’s business since the company’s formation in 1999 in the Gunnedah Coal Basin in northeastern New South Wales, Australia.
A challenge of context
“Mining is a very dynamic environment,” said John Cass, Manager of Operational Technology at Whitehaven. “Keeping our workforce safe is our number one concern — not just our people, but the contractors who support us as well.”
Vehicle interactions are among the biggest risks in open-cut operations. Whitehaven had already introduced vehicle hierarchy protocols to reduce interaction risk, but its next step was about context: helping operators see what’s happening around them — and understand why.
The company began by implementing Hexagon Operator Alertness System (OAS), designed to detect fatigue and distraction. Then came Hexagon Collision Avoidance System (CAS), which shows operators nearby equipment and relative positioning. Together, they form a connected layer of insight that gives operators a clearer, real-time view of their working environment.
More than mining alarms
“The largest benefit comes before the alarms,” Cass explained. “Giving operators a map that shows other vehicles and their position relative to their own — that’s 90% of the value.”
At Whitehaven’s Gunnedah operations, that visibility transformed how teams communicate and move. “The feedback and uptake of the systems on site have been amazing,” said Grant Phillips, Health and Safety Superintendent. “It’s improved the positive communication on site because people know exactly how far they are from others.”
For operators like Daisy Lamb, the difference is practical. “At night shift it’s always imperative that you stay awake,” she said. “The OAS system is really effective — a good tool to have in the truck.”
Mining integration that delivers insight
The story didn’t end there. When Whitehaven and Hexagon worked to integrate OAS with CAS, the result was a world first: OAS 7.5, which automatically captures and displays video of predicted collision events. Safety personnel can now review those moments in real time, gaining a richer understanding of what’s happening in the field and why.
What began as a 500-hour field trial stretched beyond 10,000 operating hours across an entire fleet — proof of both durability and value.
“It was a smooth, flawless journey,” said Cass. “We can now review a week’s worth of collision alerts with context, verify what’s working, and tune the system accordingly.”
A shared pursuit of safety
For Whitehaven, the collaboration underscored what’s possible when innovation meets commitment.
“Whitehaven is not shy of introducing something new,” said Mine Manager Craig Sullivan. “We always strive to be the best we can as a business — and it shows in our results.”
The success of the OAS 7.5 integration has set a new benchmark for proactive safety. As Hexagon’s Mining division President, Dave Goddard noted, the release “reaffirms our commitment to delivering industry-leading safety solutions that support customers in achieving their zero-harm goals”
By linking operator alertness with collision awareness, Whitehaven has turned data into context — and context into safer operations. For a company committed to looking after its people, that’s technology doing what matters most.
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.