(Virtual Showroom) Immersive Technologies has announced the winners of its 16th annual Global Business Improvement Award which acknowledges the most outstanding results achieved by mining companies who use simulation as a key driver in mining operation and workforce development optimization.

Category winners are selected from customers across
54 countries for their achievements in continuously improving mining workforce safety, productivity, machine reliability, through strategic workforce development-based initiatives. These projects demonstrate excellence in aligning people, process, and technology to push the mining performance envelope across any OEM make, this year’s winners conducted continuous improvement projects on mixed fleets including Komatsu, Caterpillar®, Hitachi and Komatsu (P&H).

Global Award Winners:

• Safety – PT Kaltim Prima Coal, Sangatta (Indonesia)
• Reliability – Anglo American, Sishen (South Africa)
• Productivity – Kinross, Bald Mountain (United States)
• Training Effectiveness – CSN, Casa de Pedra (Brazil)
• Community Development – Mineral Resources, Osborne Park (Australia)

PT. Kaltim Prima Coal (KPC) operates one of the largest coal mines in Indonesia, located in the Sangatta region of East Kalimantan. The company manages two main mining areas: the Sangatta and Bengalon mines. Over the years, KPC has expanded its operations and continues to play a crucial role in the local economy. This year KPC completed a project focused to improve safety and machine care for operators of their Cat® 785B and Cat® 789D haul trucks.

Real Results include:

• 78% improvement in workforce risk profile (operating errors)
• 11% reduction in overall haul truck events related to safety and machine care 

19% reduction in engine overspeed

52% reduction in brake temps

“The improvement project has significantly reduced real machine events through targeted operator training and helped us meet company expectations regarding safety, productivity and machine health. The improvement is visible consistently through our weekly machine events
data review. This gives us real evidence that operators have improved their operation skill and knowledge. We look forward to our next targeted training project, likely around fuel efficiency and productivity.”

Mining at Sishen in South Africa dates back to 1953 and today is carried out by Anglo American’s Kumba Iron Ore division. More than 900 million tonnes of iron ore have been produced during 60 years of the mine’s operation. This year Sishen embarked on a strategic workforce development project to improve machine reliability through targeted training leveraging their Immersive Technologies PRO5 simulator platform.  The goal of the project was to train best practice operating technique to efficiently and safely reduce machine wear and tear on their fleet of Komatsu haul trucks and P&H 4100 rope shovels.

Real Results include:

Haul Truck:

• 96% decrease in service brake application at high speed
• 22% reduction in truck overloads
• 60% reduction in frame torques

Rope Shovel:

• 94% reduction in swing impacts
• 97% reduction in hoist brake not set while hanging
• 72% reduction in hoist stall
• 98% reduction in boom jacks

“The implementation of simulator-based training as part of the Operate for Reliability (O4R) program has delivered measurable improvements across key operational metrics at Sishen mine By focusing on the practical application of training, operators have shown significant reductions in operational errors, enhanced adherence to safety protocols, and better machine handling practices. These improvements will have a direct impact to the business in the form of reduced component wear, fewer maintenance interventions, and increased productivity.”

Kinross Bald Mountain mine is an open-pit gold mine located in White Pine County, Nevada. The operation employs around 520 people and has significantly contributed to Kinross' global production. This year the mine completed a strategic workforce development project with Hitachi EX5600-6 operators to boost ore production while reducing variability in shovel performance.

Real Results include:

• Reduced load times by 14.17%
• Held truck payloads steady while increasing bucket payloads by 12.22% overall, which reduced bucket count by 14%.
• Achieved 92% pass rate on safety events

"The shovel improvement project could only be as successful as the tools and mindset that goes into it. The simulator is an outstanding tool for training and evaluations. But it is not a solve all or solitary solution. Carrying the lessons from simulation and classroom to field application and coaching is crucial. Having a leadership and training team as supportive as we do is just as important to generating the operator buy in and enthusiasm that came into the project. When all the parts come together correctly; it becomes a smooth machine providing sustained results."

CSN Mineração is located in the city of Congonhas, 90 km from Belo Horizonte, in the state of Minas Gerais, Brazil. The company is the second-largest exporter of iron ore in Brazil and the seventh-largest in the world. This year, CSN carried out a strategic workforce development project in partnership with Immersive Technologies to enhance the effectiveness of its Cat® 793F and Cat® 793D training programs.

Real Results include:

• 45% reduction in practical hours required to reach proficiency
• 1.4% increase in productivity among simulator-trained operators 
• 12% reduction in maneuvering time for simulator-trained operators

“I would like to thank CSN and our partner Immersive Technologies for the excellent work in developing tailored simulator curricula for new operator training. The goal was to reduce practical training time, maneuvering time, and average speed of off-highway trucks. The results of the project were very positive. We achieved significant improvements in safety and instructor efficiency. Additionally, we reduced the waiting time for loading equipment, as new haul truck operators completed training with enhanced operating skills.”

Headquartered in Perth, Western Australia, Mineral Resources (MinRes) is a recognised market leader in delivering mining services to some of the world’s largest mining companies. MinRes is also growing its own world-class portfolio of iron ore and lithium operations. This year MinRes utilized its state-of-the-art centralised training facility, equipped with Immersive Technologies LX Series, PRO4 and PRO5 advanced equipment simulator platforms, to foster community development through skills training and new operator onboarding for its workforce in Western Australia.

Real Results include:

• Over 538 haul truck operators trained
• Over 111 excavator/loader operators trained
• 113 auxiliary equipment operators trained

“Incorporating simulator training into our Entry Level Operator Program has meant that we can train new operators safely, to company expectations and nationally recognised standards, in shorter time periods than before. The scenarios we use develop safe, competent and confident operators who, over time and with on-site training, improve their efficiencies in tasks such as correctly approaching load units, tipping and using multiple braking systems. The focus on machine health during simulator training helps operators understand how to operate the machine to their best capabilities while contributing to reduced down time due to maintenance work. The success demonstrated in our initial program has led to sim training being the first stage in subsequent programs, which continue to support the development of our people as they progress in their careers.”