Mining & Metallurgy • MN-01
Integrated Fuel Balance
Close the gap between fuel bought, fuel issued and fuel actually burned.
Scope
What the engagement covers.
Fuel is often the largest controllable cost on a mine and the least reconciled. Integrated fuel balance measures every transfer point so the difference between purchased, dispensed and consumed volume is explained rather than written off as shrinkage.
Included capabilities
- Level, flow and dispensing measurement across tanks, bowsers and equipment
- Automatic equipment identification at the point of refuelling
- Consumption modelling by equipment class, load and operating condition
- Automated reconciliation with variance thresholds and exception cases
- Fraud scenario detection covering siphoning, ghost issues and meter tampering
Outputs and deliverables
- Fuel measurement architecture across all transfer points
- Consumption model per equipment class
- Automated reconciliation with exception register
- Loss reduction reporting against verified baseline
Workflow
How it is delivered, step by step.
Each step has an owner, an entry condition and an artefact that has to exist before the next step begins.
01BaselineMap every fuel transfer point, current measurement and known loss rate.
02InstrumentTank gauging, flow meters, dispenser controllers and equipment tags.
03ModelExpected consumption per equipment class, load profile and terrain.
04ReconcileAutomated balance across purchase, storage, issue and burn.
05InvestigateStructured exception workflow with evidence and accountability.
Use cases
Where this is typically applied.
Operations with remote refuelling points and limited supervision
Groups standardizing fuel accounting across several mines
Delivery model
The operating pattern for Mining & Metallurgy.
The same delivery discipline applies across every capability in this line, so combined engagements stay coherent.
Survey
Fleet, fuel flow, network coverage, loss points and current dispatch practice.
Instrument
On-board units, sensors, tags, LiDAR and camera installation.
Calibrate
Baseline consumption, cycle times, volumes and alert thresholds.
Operate
Dispatch centre, driver feedback loops, investigation and reporting routines.
Optimize
Continuous tuning against production, cost and safety targets.
Integration
- Fleet management, weighbridge and laboratory systems for reconciliation.
- ERP and fuel procurement for cost and inventory alignment.
- Mine planning and survey data for haul route and grade context.
- Access control and HR systems for shift, competency and permit checks.
Engagement approach
Fuel, cycle time and safety losses are quantified before deployment, and the same measures are the acceptance criteria after go-live, so value is settled on evidence rather than opinion.
Related
Other capabilities in Mining & Metallurgy.
MN-02
Mining Dispatch
Match trucks to shovels continuously instead of by shift plan.
MN-03Cargo Volume Recognition
Measure what is actually in the tray, load by load.
MN-04LiDAR & Computer Vision
Give the site a geometric and visual sense of itself.
MN-05Personnel Positioning
Know who is underground, in the pit and in the danger zone, right now.
MN-06Workforce Safety
Manage fatigue, competency and behaviour as measurable risks.
MN-07Tire Analytics
Extend the life of one of the largest consumables on site.
MN-08Digital Driver Advisor
Coach the operator in the cab, in the moment.
MN-09Ore Quality Management
Deliver the grade the plant was designed for, consistently.
MN-10Theft Prevention
Remove the opportunity, then prove what happened when it is taken anyway.
MN-11BI & Dispatching Center
One control room where production, cost and safety are seen together.