Future-proofing SA mining with CPS on TMM

By Dushendra Naidoo – head of Safety and Sustainable Development at the Minerals Council South Africa

Introduction

As South African mining evolves to meet global sustainability and safety standards, Trackless Mobile Machinery (TMM) installed with Collision Prevention Systems (CPS) has emerged as a pivotal innovation for enhancing safety, efficiency and competitiveness. Under the overarching theme of “Future-Proofing African Mining,” this thought leadership piece explores the current status of TMM and CPS in South African mining operations, the opportunities and challenges these technologies present, and the roadmap for a resilient and sustainable mining ecosystem.

At the heart of this transformation lies the Minerals Council South Africa’s unwavering commitment to Zero Harm, exemplified by its substantial financial investment in the multi-year special project “Industry Alignment on TMM Regulations”. This initiative represents a holistic, risk-phased, and collaborative approach to ensuring compliance with TMM regulations while balancing the critical priorities of saving lives and safeguarding livelihoods. The Minerals Council South Africa Project Team embarked on a comprehensive journey through the execution of the special project that included a review of the work done previously by EMESRT (Earth-Moving Equipment Safety Round Table) and other entities both locally and internationally.

The Minerals Council’s special project has led to the production of world-leading guidance documentation to assist mining industry stakeholders in ensuring that “due-diligence” is catered for through the process of assessing operational requirements and where a CPS is required, the CPS ecosystem requirements are reviewed in totality. Technology is certainly not a “silver-bullet” solution and operational aspects such as traffic management and “reasonably practical measures” also need to be considered through a risk-phased assessment prior to the implementation of technology. In my opinion, currently in our era, the successful implementation of technology is only as good as the people and systems that support the technology.

 

Challenges

Mining operations across South Africa have made significant strides in adopting TMM with CPS technologies to address transport-related accidents, one of the most persistent safety challenges. These systems integrate advanced sensors, proximity detection and automated braking technologies to prevent collisions between vehicles, equipment and personnel. The introduction of TMM sub-regulations has catalysed widespread adoption, driving a culture of safety innovation.

However, achieving compliance has been far from straightforward. The technical complexity of CPS implementation has demanded rigorous coordination among various stakeholders, including mining companies, Original Equipment Manufacturers (OEMs), Operational Technology Managers (OTMs), unions, government departments including the Department of Mineral Resources and Energy (DMRE) at the time – now, the Department of Minerals and Petroleun Resources (DMPR),  Mine Health and Safety Council, international bodies ICMM (International Council of Mining and Metals), EMESRT (Earth-Moving Equipment Safety Round Table), international technology bodies and academic and research institutions. This collaborative effort ensures a shared responsibility for developing, installing, maintaining and improving CPS technologies.

Aside from collaboration, the many stakeholders located across the country required a clear understanding of the technical aspects and alignment on interpretation of the TMM regulations. This, to a large extent, was achieved through the regional workshops that were conducted by the Minerals Council’s MOSH (Mining Industry Occupation Safety and Health) T&M (Transport & Machinery) team. A process map (Figure 1) designed by the team represents a defined guidance pathway for mines to follow when reviewing their individual status towards compliance with the TMM regulations.¹

 

It is important to note that further work is being done through the special project on the following² :

Data gathering and case study development: Comprehensive collection of data and development of case studies to inform localisation strategies and operational compatibility of CPS components.

Mine site visits: Conducting on-site assessments to test ambient environments, specifically evaluating the impacts of electromagnetic interference (EMI) and electromagnetic compatibility (EMC) on CPS performance.

Test specification refinement: Updating CPS Test Specification Verification parameters based on lessons learned in previous project phases to enhance reliability and applicability.

Stakeholder engagement: Ongoing collaboration with key stakeholders, including OEMs and mining operators, to align on critical issues and attain consensus on localisation priorities.

Technical guides development: Producing expert-informed guidance on essential CPS aspects, such as “Fail to Safe Without Human Intervention,” ensuring operational safety and compliance.

Learning from lived experiences: Undertaking technical mine site visits to gather first-hand insights into the practical challenges and solutions encountered by mines, OEMs, and Original Technology Manufacturers (OTMs) in implementing TMM regulations.

The path to CPS implementation is fraught with challenges:

Technical barriers: The integration of CPS technologies with existing TMMs requires overcoming technical hurdles such as electromagnetic compatibility and data interoperability.

High costs: The financial investment for implementing CPS, particularly for smaller mining operations, poses a significant barrier.

Workforce adaptation: Training and upskilling employees to operate and maintain advanced systems requires comprehensive strategies to mitigate resistance and build capability.

Lack of co-operation from OEMs: This includes hurdles such as exclusive non-disclosure agreements (NDAs), some OEMs are averse to working with different PDS suppliers and do not fully comply to specifications.

Lack of adequate testing facilities (old underground mine layouts).

Technology is not yet ready: Immature technology, installed CPS not meeting all the new requirements, cap lamp development and certification required, setting of zones not easy when CPS is out of the line of sight, faulty components, poor or lack of interface and integration with other equipment.

Technology unavailability:  There is no one supplier that provides a full solution, an interface back to the machine is always required , which results in the involvement of at least three suppliers, namely the OEM of the equipment, the CPS system supplier and the interface system supplier. Some suppliers are also still developing products to answer this call.

Testing and verification are critical to ensure correct system functionality and performance, and this takes time. The number of entities available to assist with testing (i.e., external 3rd party entities) adds to complexity.

Lack of standardisation across new/intelligent versus older/non-intelligent models (legacy machines).

Limited suppliers looking to service a significant short-term demand and lack of hardware availability due to high demand are further constraints. A global shortage of microchips used in the manufacture of CxDs (Collision Warning and Avoidance Devices) has been highlighted.

Long timelines for commercial selection of CxD suppliers.

Mixed observations about the effectiveness of the CPS with some saying it is effective, not perfect, not a silver bullet and ineffective if not managed well including proper management routines (project management, procurement, change management, verifications, performance standards).

 

Opportunities: Advancing mining safety, efficiency, leadership

To overcome existing challenges and fully capitalise on the potential of Trackless Mobile Machinery (TMM) with Collision Prevention Systems (CPS) technologies, the mining industry must prioritise collaboration, innovation and sustainability. By developing a united effort among stakeholders and leveraging cutting-edge solutions, the sector can achieve transformative improvements in safety, efficiency and global competitiveness.

 

Enhanced safety and risk management

CPS have the potential to play a transformative role in the mining industry’s journey toward achieving the Zero Harm objective. By addressing transport-related hazards, these systems aim to significantly reduce the risk of injuries and fatalities. However, the effectiveness of CPS technologies depends on proper maintenance, rigorous training of operators, and careful integration into operational environments. Without these critical elements, CPS could introduce new risks, including potential harm to personnel if systems fail or are misused.

When well-implemented, CPS can provide a foundation for improving safety by offering advanced traffic management solutions and integrating with broader operational controls. Real -time monitoring and predictive analytics have the potential to enhance risk management by identifying and mitigating hazards proactively. Nevertheless, the successful adoption of CPS requires a commitment to sustained training, maintenance, and oversight to ensure the technology delivers on its promise of safer, more reliable operations. This measured approach recognises both the promise and the challenges of CPS, emphasising the importance of continuous improvement and responsible implementation to achieve lasting safety advancements.

Alignment with ESG principles

The deployment of TMM with CPS technologies underscores the mining sector’s commitment to Environmental, Social, and Governance (ESG) principles. By prioritising worker safety and minimising accident-induced environmental damage, these technologies affirm the industry’s dedication to sustainable operations. Furthermore, localising the manufacturing of CPS components supports job creation and economic empowerment, aligning with the United Nations Sustainable Development Goals (SDGs) by stimulating community development and long-term societal benefits.

 

Conclusion

The journey toward Zero Harm in the South African mining industry is one of partnership, innovation, and resilience. Mining companies, in close collaboration with the DMPR , are demonstrating their commitment to complying with TMM regulations while actively seeking innovative measures to reduce risks. This alignment underscores a shared responsibility to protect lives and livelihoods.

Through the adoption of CPS, the industry is laying a strong foundation for improved safety and operational excellence. However, technology alone is not the solution. Mining companies are complementing these advancements with tailored risk-reduction strategies, the adoption of the MOSH traffic management leading practice, and comprehensive training programs to spark a culture of safety at every level.

South Africa’s proactive stance on TMM regulations and the early adoption of CPS technologies place its mining industry at the forefront of global safety innovation. By stimulating global partnerships and driving technological advancements, South Africa solidifies its role as a pioneer in the mining sector, capable of setting global safety and operational standards for the future. This comprehensive approach highlights how advancing mining safety through CPS technologies not only protects lives but also drives efficiency and ultimately alignment with global sustainability goals.

As the industry continues to refine its approaches, leveraging lessons learned and advancing technological capabilities, the remaining challenges will gradually transform into opportunities for improvement. With time and dedication, the CPS and TMM journey will achieve its full potential, safeguarding lives and ensuring a sustainable future for African mining. This collective effort reinforces the commitment to Zero Harm and sets the stage for a resilient and competitive mining ecosystem.

References: Visit https://africanmining.co.za for the process flow diagram

For additional information visit https://www.mosh.co.za/transport-and-machinery/documents

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