{"id":6466,"date":"2025-09-03T20:04:35","date_gmt":"2025-09-04T00:04:35","guid":{"rendered":"https:\/\/blog.hexagonmining.com\/?p=6466"},"modified":"2025-09-03T20:04:55","modified_gmt":"2025-09-04T00:04:55","slug":"how-drill-assist-is-slashing-training-time-while-boosting-productivity","status":"publish","type":"post","link":"https:\/\/blog.hexagonmining.com\/en\/how-drill-assist-is-slashing-training-time-while-boosting-productivity\/","title":{"rendered":"How Drill Assist is slashing training time while boosting productivity"},"content":{"rendered":"

By Neville Judd<\/p>\n

Of all the mining processes ripe for automation, blasthole drilling is up there.<\/span>\u00a0<\/span><\/p>\n

Firstly, it\u2019s a labour- and capital-intensive process; delays in drilling affect the rest of the mine. Secondly, there\u2019s a growing talent shortfall of drillers across the world\u2019s mines.<\/span>\u00a0<\/span><\/p>\n

According to Curtis Stacy, it takes a person three to five years to become a good driller. <\/span>Hexagon Drill Assist<\/span><\/a> changes that.\u00a0<\/span>\u00a0<\/span><\/p>\n

Stacy is a senior product manager at Hexagon and co-founder of Phoenix Drill Control. In June, Hexagon acquired Drill Assist, a blasthole drilling automation technology developed by Phoenix Drill Control.<\/span>\u00a0<\/span><\/p>\n

Drill Assist is an artificial intelligence-powered automation technology that\u2019s designed to work like an expert operator. It can be used at nearly every step of the blasthole drilling process, on any kind of drill. Using an AI algorithm, Drill Assist continually optimises the drilling process, resulting in improved penetration rates, greater machine availability, and reliable downhole data.<\/span>\u00a0<\/span><\/p>\n

\u201cThe ability to train an operator in 15 minutes and instantly increase their productivity and quality of drilled holes can transform an entire workforce into expert drillers in a matter of days, not years,\u201d said Stacy.<\/span>\u00a0<\/span><\/p>\n

\u201cWe successfully trained an operator by text message during a night shift at a North American iron mine,\u201d Stacy added.\u00a0<\/span>\u00a0<\/span><\/p>\n

The system can be disengaged instantly, returning full control to the operator. \u201cYour drill remains just as you purchased it, with no additional technician training and minimal additional maintenance, but with increased productivity.\u201d<\/span>\u00a0<\/span><\/p>\n

Transforming <\/span>drilling at Capstone Copper<\/span><\/span>\u00a0<\/span><\/h2>\n

Joe Kalkus, senior mine coordinator at Capstone Copper\u2019s Pinto Valley mine in Arizona, has seen the benefits of Drill Assist first hand.<\/span>\u00a0<\/span><\/p>\n

\u201cFinding people in mining is challenging these days,\u201d said Kalkus in a <\/span>video interview<\/span><\/a>. \u201cDrill Assist can take a green driller and turn them into a 20-year veteran after a three-hour training. It\u2019s been the best drilling software, drilling program, that I\u2019ve seen in my career.\u201d<\/span>\u00a0<\/span><\/p>\n

Pinto Valley Mine drill operator, Robin Toot, echoed Kalkus\u2019s praise for Drill Assist.<\/span>\u00a0<\/span><\/p>\n

\u201cI learn something new every day and I\u2019ve been doing this for a long time,\u201d said Toot. \u201cIt\u2019s helped me quite a bit. In fact, every hole I\u2019ve ever drilled with it has been a nice, clean, good hole.<\/span>\u00a0<\/span><\/p>\n

\u201cThe training time for the Drill Assist was really quick. You just have basically one button you push, and it\u2019ll run right through its program from levelling the drill out, to drilling, to finishing out the hole. I would say in three hours I can teach you how to drill with it.\u201d<\/span>\u00a0<\/span><\/p>\n

Hexagon has enhanced Drill Assist to support down-the-hole (DTH) hammer drilling and multi-pass drilling.\u00a0<\/span>\u00a0<\/span><\/p>\n

\u201cWhile the AI algorithms have not changed in some time, additional functionality including the ability to hammer drill and track multi-pass hole depth have been implemented,\u201d said Stacy.<\/span>\u00a0<\/span><\/p>\n

Drill Assist operates as an automation layer above OEM control systems, using existing rig sensors to manage drilling processes and reduce manual input. It requires no extra sensors for multi-pass tracking.\u00a0<\/span>\u00a0<\/span><\/p>\n

\u201cThe multi-pass system requires no additional sensors to track the rod length down the hole!\u201d Stacy said. \u201cThe rod add-and-remove functions are still performed by operators.\u201d<\/span>\u00a0<\/span><\/p>\n

\"\"

Joe Kalkus and Curtis Stacy discuss Drill Assist at Capstone Copper’s Pinto Valley mine<\/p><\/div>\n

Errors eliminated and productivity up 30%<\/span><\/span>\u00a0<\/span><\/h2>\n

Drill Assist has been deployed globally, most recently at a South American iron ore project. \u201cThe miner was struggling with hole quality issues, primarily drill to depth,\u201d Stacy explained. \u201cThe AI-based hole-quality algorithms, along with high-precision machine guidance, eliminated driller-induced errors and reduced re-work.\u201d\u00a0<\/span>\u00a0<\/span><\/p>\n

Initial productivity gains of 30% seen in copper mining were replicated in iron mining, with DTH hammer drilling showing similarly strong results.<\/span>\u00a0<\/span><\/p>\n

The system also delivers significant cost and environmental benefits. \u201cA mine site is evaluating the potential of parking one of four drills, cutting drilling costs by an additional 25%,\u201d Stacy said.\u00a0<\/span>\u00a0<\/span><\/p>\n

Future development may include improved blast planning and full automation. \u201cUse of our measurement while drilling (MWD) data for custom blast loading is currently in testing,\u201d Stacy said, adding that this could further reduce energy consumption.\u00a0<\/span>\u00a0<\/span><\/p>\n

Fully autonomous drilling is the goal. Users will have minimal interaction as rigs autonomously determine and execute drilling patterns, said Stacy.<\/span>\u00a0<\/span><\/p>\n