Shanagan Coal Mine
An open-pit coal operation in Mongolia turned five disconnected problems into one live model, and paid back the platform inside a quarter.
Five blind spots, no single view.
Shanagan had cameras, a fleet-management tool, and a survey crew, but each lived in its own silo. Safety depended on who was watching. Fuel walked off site. Contractor invoices couldn't be checked against reality. And tonnage was reconciled too rarely to trust.
- Safety violations reviewed only after incidents.
- Unexplained fuel variance across the haul fleet.
- No way to verify contractor billing against actual activity.
- Infrequent, manual tonnage and slope surveys.
A phased rollout, highest value first.
Rather than a big-bang deployment, Nexus sequenced the rollout to pay for the next phase with the savings from the last.
AI Vision at the bench
Existing cameras were connected to a Nexus edge node running PPE, intrusion, and proximity detection in real time.
Fleet & fuel telemetry
Haul-truck movement and fuel data were ingested to surface idling, theft, and inefficiency across the fleet.
Billing reconciliation
Gate, fleet, and vision data were cross-referenced against contractor invoices to recover over-billed hours.
Tonnage & stability
Drone volumetrics and satellite InSAR added independent tonnage estimates and slope-movement early warning.
What changed on the ground.
Recovered contractor billing
Cross-referencing gate, fleet, and vision data surfaced over-billed contractor hours.
Reduced fuel variance
Idling, theft, and inefficiency across the haul fleet became visible and addressable.
Higher PPE compliance
Real-time, automated enforcement lifted compliance on every active bench.
Rapid return on investment
The phased rollout paid for itself within a single quarter.
“We stopped arguing about what happened on the bench. The data was just there, safety, fuel, billing, tonnage, on one screen. It paid for itself before we'd finished rolling it out.”
From one pit to the whole operation.
With the core platform proven, Shanagan is extending coverage to adjacent pits and adding predictive maintenance on the haul fleet, all on the same digital twin.
Run the same playbook on your site.
Book a session with our mining team and we'll sequence a phased rollout against your highest-value problem first.