Proactive Insights
Review recorded findings from production, tailings, ground, fleet, supply and energy, with measured evidence and accountable follow-up.
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A$145.7M a year is sitting in open findings
- 28 of them are critical or urgent and carry A$89.7M of that.
- Most of the exposure is in coal at A$138.8M.
- 3 are upside, not risk — A$4.9M available if taken.
DL-01 moving 38.8k bcm/day less than its baseline
critical · A$26.3M / yr
Product CV falling 5.5 kcal/kg/day — 9 days to the 5850 NAR rejection limit
critical · A$11.7M / yr
Product Stockpile P3 (long-term): 71°C and rising 2.1°C/day — spontaneous combustion risk critical
critical · A$514K / yr
Airborne dust and respirable crystalline silica: TARP level 1
Controls verified; review or TARP status needs attention.
Verify the listed critical controls in the field this week, close overdue actions, and record verification evidence against each control. Escalate any not-effective control to the SSE.
DL-01 moving 38.8k bcm/day less than its baseline
A$26.3M
a year at stake
7-day availability 65.1% vs 86.5% baseline; cycle 63.8s vs 58.1s; fill factor 0.88 vs 0.95; 28 boom strain alarms in 7 days. Dragline overburden is the cheapest bcm on site, so every bcm it doesn't move is re-handled by truck and shovel or delays coal exposure.
Complete boom chord NDT and strain-gauge review, confirm safe operating envelope, then restore full duty. Re-sequence truck & shovel onto dragline-deficit benches to protect coal exposure.
Product CV falling 5.5 kcal/kg/day — 9 days to the 5850 NAR rejection limit
A$11.7M
a year at stake
7-day product averages 5902 kcal/kg NAR at 15.3% ash. 48 of 57 trains in 28 days were below the 6000 target and 4 below rejection. ROM samples show the Glen Munro seam rising in the mix.
Re-blend at the ROM pad (raise Hebden share), drop the DMC cut-point RD by 0.02–0.03 to lift CV at the cost of some yield, and use the blend optimiser to set the stack order for the next vessel. Notify marketing if any cargo is at risk of rejection.
Product Stockpile P3 (long-term): 71°C and rising 2.1°C/day — spontaneous combustion risk critical
A$514K
a year at stake
96,000 t, 52 days since formed, 4 hotspots, not compacted. At the current rate it reaches 80°C in about 4.3 days. Heating also degrades CV (oxidation) and creates a fire and fume hazard for reclaim crews.
Reclaim this pile first (first-in first-out) onto the next trains, dig out and spread hotspots under the spontaneous combustion TARP, compact and profile the remainder, and increase thermal survey frequency to daily.
Spontaneous combustion — stockpiles, spoil and exposed seams: 3 critical controls not assured; PHMP review overdue; TARP level 2
Weekly stockpile thermal survey with TARP — partially effective, verification overdue since 2026-10-24; First-in first-out stockpile reclaim / maximum residence time — not effective, verification overdue since 2026-10-10; Compaction and profile control of long-term piles — not verified, verification overdue since 2026-10-04
Verify the listed critical controls in the field this week, close overdue actions, and record verification evidence against each control. Escalate any not-effective control to the SSE.
CHPP yield gap widened to 4.5% (baseline 2.9%)
A$32.8M
a year at stake
Actual yield is 4.5 points below washability. DMC Ep 0.041 vs 0.026 baseline and magnetite 0.94 kg/t vs 0.63 kg/t point to cyclone wear (apex / vortex finder) or medium density control, not a feed change. Coal is going to reject that the float-sink says is saleable.
Inspect DMC apex and vortex finders and replace worn spigots at the next CHPP maintenance day; run a tracer (density tracer) test to confirm Ep; check medium density control loop and magnetite recovery (magnetic separator efficiency).
EX-03 (Liebherr R 9600) down unplanned — availability 71% vs 85% target
A$14.2M
a year at stake
MTBF 62 h. A prime excavator out takes its truck fleet with it; 10 h of breakdown delay logged against it in 28 days.
Run a bad-actor RCA on hydraulics and swing drive; check component life (swing drive near end of life) and bring the change-out forward rather than repair-in-place.
DL-01 drag rope at 96.1% of life — about 7.4 days left
A$2.2M
a year at stake
2788 h on rope against 2900 h expected life at 15.1 operating h/day. A rope failure in service is an unplanned outage of 24–36 h plus a dropped-load hazard.
Plan the drag rope change into the next planned dragline shutdown before 2026-10-30; confirm rope and sockets are on site.
2 open structural crack indications on DL-01
Open NDT indications on tub/boom combined with rising boom strain alarms. Structural integrity is the dominant long-term dragline risk.
Engineer-of-record review of indications; set repair-or-monitor decision with crack-growth inspection interval.
Exposed coal falling 2,855 t/day — 9.6 days of cover
Prime overburden removal is behind plan, so coal is being mined faster than it is uncovered. If this continues the pit becomes coal-starved and ROM falls regardless of fleet availability.
Prioritise prime stripping on the strips that release the most coal per bcm; review dragline recovery plan and truck & shovel bench allocation at the weekly plan meeting.
CV-02 Overland product conveyor: 2 defective splices and rip detection faulted
A splice failure or longitudinal rip on a steel-cord belt is a multi-day outage. 37 idlers flagged on the latest survey (also a fire ignition source).
Restore rip detection to service, schedule splice repair or re-splice at the next planned stop, and change out flagged idlers.
Fire on mobile and fixed plant: 1 critical control not assured
Fire suppression systems tested on haul trucks and excavators — not verified, verification overdue since 2026-10-15
Verify the listed critical controls in the field this week, close overdue actions, and record verification evidence against each control. Escalate any not-effective control to the SSE.
Muswellbrook receiver (east): pm10 24h 44.2 µg/m³ against 50 limit (11.6% headroom)
1 readings at or above the internal trigger in 14 days. A consent exceedance is a reportable incident and community issue; operational controls are cheaper than lost production from a forced stop.
Tighten the real-time dust TARP for north-westerly winds: suspend exposed dumps on the receiver side, add water cart passes, and pre-plan alternative dump locations so production is not lost.
CV-04 Reclaim to train loadout: 1 defective splices
A splice failure or longitudinal rip on a steel-cord belt is a multi-day outage. 19 idlers flagged on the latest survey (also a fire ignition source).
Restore rip detection to service, schedule splice repair or re-splice at the next planned stop, and change out flagged idlers.
9 of 66 trains cancelled in 28 days (13.6%)
A$2.4M
a year at stake
Main cause: rail network. 90,684 t not railed against plan; product stockpiles now 611,000 t (26.3 days of rail plan). When product stockpiles fill, the CHPP goes stockbound and ROM backs up.
Request make-up paths with the rail operator and terminal, re-sequence the vessel stem, and keep emergency stockpile capacity free so the CHPP is not throttled.
ROM 96.6% of plan over 28 days (34,651 t short)
A$48.7M
a year at stake
Prime overburden at 95.4% of plan, strip ratio 6.46 bcm/t. Top delay causes: equipment breakdown 87.1 h, rail port constraint 47.3 h, stockbound 21.9 h.
Attack the top two delay categories first; they are worth more than any single asset fix.
Night-time attended monitoring — nearest residence: noise laeq15 39 dB(A) against 40 limit (2.5% headroom)
1 readings at or above the internal trigger in 14 days. A consent exceedance is a reportable incident and community issue; operational controls are cheaper than lost production from a forced stop.
Review the operating controls for this monitor and confirm the trigger response.
5 major fleet components at ≥90% of life
EX-05 Main hydraulic pumps (set) 99.2% (100 h left, 60 d lead); HT-217 Engine 99.1% (200 h left, 140 d lead); EX-03 Swing drive 96.7% (600 h left, 120 d lead); HT-228 Final drives (pair) 92% (1275 h left, 90 d lead); HT-211 Tyres (set) 90.8% (641 h left, 45 d lead)
Confirm exchange components are ordered for anything whose remaining hours are shorter than its lead time; plan change-outs into scheduled services.
Roads and other vehicle operating areas: 2 critical controls not assured
Windrows at ≥ 1/2 wheel height on all ramps and dumps — partially effective, verification overdue since 2026-10-21; Haul road design and maintenance standard — not verified, verification overdue since 2026-10-15
Verify the listed critical controls in the field this week, close overdue actions, and record verification evidence against each control. Escalate any not-effective control to the SSE.
Highwall and spoil stability: 1 critical control not assured; TARP level 1
Exclusion zones at dragline spoil toe — partially effective, verification overdue since 2026-10-24
Verify the listed critical controls in the field this week, close overdue actions, and record verification evidence against each control. Escalate any not-effective control to the SSE.
Blast monitor — nearest residence: blast overpressure 115.6 dB(L) against 120 limit (3.7% headroom)
1 readings at or above the internal trigger in 14 days. A consent exceedance is a reportable incident and community issue; operational controls are cheaper than lost production from a forced stop.
Review blast design (MIC, stemming, initiation timing) and weather window for blasts near the receiver; consider reduced charge for the next shots.
BEN Dragline (primary overburden) carries a 0% chance of failure in the next 30 days
Health score 52, status operational, 21 days of predicted useful life remaining, rated mission critical criticality.
Bring BEN Dragline (primary overburden) into the next planned maintenance window rather than waiting for an unplanned outage.
Dragline hoist motor (rotable) has 0 days of cover against a 60 day lead time
A$350K
a year at stake
0 in stock against 0.1 used per month leaves 60 days uncovered if this critical part is called for, and it comes from Hunter Valley Electrical Services (DEMO).
Reorder 1 units of DL-MTR-HOIST-ROT to close a 60 day exposure window.
Dragline hoist rope 83 mm (pair) has 0 days of cover against a 21 day lead time
A$260K
a year at stake
0 in stock against 0.3 used per month leaves 21 days uncovered if this critical part is called for, and it comes from Bridon-Bekaert Ropes Group (DEMO).
Reorder 1 units of DL-ROPE-HOIST-83 to close a 21 day exposure window.
Sizer gearbox exchange unit has 0 days of cover against a 90 day lead time
A$410K
a year at stake
0 in stock against 0 used per month leaves 90 days uncovered if this critical part is called for, and it comes from MMD Australia (DEMO).
Reorder 1 units of SZ-GBX-625 to close a 90 day exposure window.
793F C175-16 engine (exchange) has 0 days of cover against a 140 day lead time
A$720K
a year at stake
0 in stock against 0 used per month leaves 140 days uncovered if this critical part is called for, and it comes from Westrac (Caterpillar) (DEMO).
Reorder 1 units of 793F-ENG-C175 to close a 140 day exposure window.
Renewable PPA on Grid electricity — dragline saves $632,400 a year
A$632K
a year at stake
Displacing 60% of this stream cuts the delivered energy cost from 135 to 118 per MWh with no capital required.
Execute the Renewable PPA — it lowers the energy bill immediately with no capital.
Trolley assist on the North ramp; renewable diesel blend on Diesel — haul, dig and support fleet saves $1,756,800 a year
A$1.8M
a year at stake
Displacing 12% of this stream cuts the delivered energy cost from 1.94 to 1.7 per litres for $38,000,000 of capital, a 21.6 year payback.
Take the Trolley assist on the North ramp; renewable diesel blend case to capital review — it pays back in 21.6 years before any carbon value.
Renewable PPA plus 20 MW on-site solar on Grid electricity — CHPP and conveyors saves $2,464,000 a year
A$2.5M
a year at stake
Displacing 70% of this stream cuts the delivered energy cost from 135 to 95 per MWh for $26,000,000 of capital, a 10.6 year payback.
Take the Renewable PPA plus 20 MW on-site solar case to capital review — it pays back in 10.6 years before any carbon value.
DMC 1000 apex and vortex finder set has 0 days of cover against a 28 day lead time
A$140K
a year at stake
0 in stock against 0.2 used per month leaves 28 days uncovered if this critical part is called for, and it comes from Multotec Australia (DEMO).
Reorder 2 units of DMC-APEX-1000 to close a 28 day exposure window.
Centrifuge basket H1000 has 0 days of cover against a 70 day lead time
A$96K
a year at stake
0 in stock against 0.1 used per month leaves 70 days uncovered if this high part is called for, and it comes from Schenck Process Australia (DEMO).
Reorder 1 units of CF-BASKET-H1000 to close a 70 day exposure window.
BEN CHPP Dense Medium Cyclone Pump carries a 1% chance of failure in the next 30 days
Health score 41, status operational, 9 days of predicted useful life remaining, rated high criticality.
Bring BEN CHPP Dense Medium Cyclone Pump into the next planned maintenance window rather than waiting for an unplanned outage.
Swing drive on EX-03 will fail before a replacement can arrive
600 hours left, about 35 days at current utilisation, against a 120 day lead time. A replacement costs $380,000.
Order the Swing drive now and plan a change-out — the lead time already exceeds the remaining life.
Main hydraulic pumps (set) on EX-05 will fail before a replacement can arrive
100 hours left, about 6 days at current utilisation, against a 60 day lead time. A replacement costs $260,000.
Order the Main hydraulic pumps (set) now and plan a change-out — the lead time already exceeds the remaining life.
Tyres (set) on HT-211 will fail before a replacement can arrive
641 hours left, about 38 days at current utilisation, against a 45 day lead time. A replacement costs $260,000.
Order the Tyres (set) now and plan a change-out — the lead time already exceeds the remaining life.
Engine on HT-217 will fail before a replacement can arrive
200 hours left, about 12 days at current utilisation, against a 140 day lead time. A replacement costs $720,000.
Order the Engine now and plan a change-out — the lead time already exceeds the remaining life.
Final drives (pair) on HT-228 will fail before a replacement can arrive
1,275 hours left, about 75 days at current utilisation, against a 90 day lead time. A replacement costs $260,000.
Order the Final drives (pair) now and plan a change-out — the lead time already exceeds the remaining life.
Screen exciter (rotable) has 0 days of cover against a 35 day lead time
A$88K
a year at stake
0 in stock against 0.1 used per month leaves 35 days uncovered if this critical part is called for, and it comes from Schenck Process Australia (DEMO).
Reorder 1 units of SCR-EXCITER to close a 35 day exposure window.
Deeper analysis
Briefings, trends and cause tracing across the whole portfolio (not filtered by site).
Value-at-stake graph
Combines asset health, sensor excursions, pressure integrity, safety barriers, bypassed trips, spares shortfalls and bottleneck economics into one A$ per day figure for each issue.
Morning briefing
26 Oct 2026 at 15:22 · run on demand
Immediate intervention is required to address critical stockouts and looming component failures that threaten the operational availability of key haulage and mining assets.
The operation is currently facing urgent supply chain vulnerabilities across multiple essential components, including haul truck engines and dragline hoist systems. With zero days of cover for several critical items and pending failures on units HT-217 and HT-228, the risk of extended unplanned downtime is significant. These stockouts jeopardize our ability to execute maintenance before failure, directly impacting production targets and equipment availability.
Trend builds after the second scan
Each scan adds a point, so you can see whether findings are being cleared or accumulating.
Intervention chains
Condition → spare parts → shutdown window → margin at risk. Calculated from records only; runs each weekday morning.
Cross-module causal analysis
38 open findings across production, fleet, supply, energy and ground. AssetMind will look for the ones that share a mechanism and collapse them into single chains with one intervention each.