Industry
Mining
Where asset-intensive operations + unplanned downtime = catastrophic margin loss.
Mining throughput is gated by SAG mill availability, conveyor health, ore-grade variance, and energy cost. The single highest-leverage operational lever is keeping the rotating equipment running and the SAG mill fed with the right ore mix. KPT's predictive-maintenance + energy-aware scheduling Optimizations target exactly that surface. A single major rotating-equipment failure caught early typically pays for the entire engagement.
How KPT helps
Predictive maintenance + energy-aware scheduling for asset-intensive ops.
Mining is the industry where Solution 2 (Quality + Predictive Maintenance) earns its keep fastest. A single SAG mill failure costs millions in lost throughput. KPT's Vibration-Anomaly Predictor catches degradation 7–14 days before it becomes a failure event — long enough to schedule a planned maintenance window instead of an emergency shutdown.
Layer on energy-aware production scheduling (Solution 1) and energy procurement (Solution 4), and the combined value is substantial. Mining operations have the highest single-day energy bills in industrial CPG — even small percentage improvements compound to seven figures.
Specific outcomes KPT delivers
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Vibration-Anomaly Predictor
IoT vibration on rotating equipment — predict failure 7–14 days out — up to 8% reduction in unplanned downtime.
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Predictive Spare-Parts Stockout
Paired with vibration prediction. Minimize MRO inventory while never blowing a stockout.
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Energy-aware Production Scheduler
Schedule energy-intensive crushing/grinding into off-peak windows — up to 4% energy cost reduction.
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Port/Mill-Gate Truck Scheduler
Slot inbound/outbound trucks to minimize queue + demurrage.
Where to start
A single SAG mill or critical conveyor system with IoT vibration retrofit. Pays for itself if it catches one major failure event in the first year. KPT will help size the retrofit + scope the PoC around your most critical asset.
Predictive maintenance for mining
Start with one SAG mill.
A 4-week assessment scopes the IoT retrofit, identifies the highest-value rotating equipment, and locks the success criteria. PoC ships in 8 weeks with shadow-run validation. If we don't catch a failure in year one, we refund the engagement.