Mining & resources decision operating system
One evidence chain connects production, plant, fleet, critical controls, maintenance, supply, energy and capital, so readiness, release and restart decisions protect output, margin and licence to operate.
Live Proof Basis:Traces every equipment condition, ore-hardness shift and stockpile buffer to real-time payable metal and margin at stake.
Open Production Intelligence01
Part 01
Why mining and resources operations need one governed decision system, and who it serves.
Start with your accountable role
Every hour the binding constraint stops, the whole value chain stops with it.
2. The Governed Question
Which constraint has the largest margin exposure this week, and what is the governed decision to close it?
3. Live Demonstration Signal
SAG Mill DEMO-SAG-101 binding constraint ($68,500/hr) — 6% Survive-to-Shutdown load derate proposed.
4. Primary Workspaces
Resources Command Center, Pit-to-Port Bottleneck Chain, Decision Queue
01 · The problem
Mines, processing plants, oil and gas facilities and their rail, port, water and power infrastructure generate more data than ever, yet critical decisions still rely on partial views.
Condition, production, integrity and supply data sit in separate systems, so no one sees the full consequence of a defect.
Operational risk: A bearing excursion in the historian is never automatically cross-checked against stockpile surge hours or supplier lead times.
Unified Intelligence Graph links SensorReading → FlowsheetStage $/hr → SparePart ETA → ReadinessPassport in one live chain.
Interventions are approved in meetings and email with no record of the basis, the accountable role or the outcome.
Operational risk: Deferred maintenance and unrecorded overrides accumulate silently until a single-point failure halts the circuit.
Decision Room enforces named role accountability, explicit alternatives, deferral cost exposure and SLA escalation.
Projected value is rarely verified after the work, so forecasts and strategies never improve.
Operational risk: Boards discount unverified ROI claims, and reliability models repeat uncalibrated false positives.
48-hour telemetry stabilization check + independent verifier sign-off into the Savings Ledger and Brier Trust Center.
02 · Who it is for
Each role sees its own priorities, drawn from the same evidence and the same decision record.
One view of what constrains throughput, margin and licence to operate.
Shift-ready Command Center, Executive Board Pack, and portfolio handover sign-off across all operating areas.
Work ranked by consequence, with the failure window and critical spare in view.
Weibull P10/P50 survival curves coupled with Mine-to-Mill ore hardness stress and verbatim O&M manual rules.
TARP triggers, monitoring currency and assurance evidence in one register.
GISTM conformance register, piezometric & slope-radar TARP triggers, and co-optimized blast/dewatering controls.
Feed quality and stage constraints traced to recovery and margin.
End-to-end flowsheet bottleneck chain, ore-margin netback simulator, and surge buffer depletion modelling.
Deferral cost, capital priority and independently verified savings.
Risk-adjusted Capital Plan governance gates and dual-custody Savings Ledger with separation of duties.
Gate-controlled handover with every test and punch item evidenced.
4-dimension Operational Readiness Passports covering safety/statutory, technical, execution and PSSR sign-off.
The story in one page
Condition data, plans, permits, spares and people sit in separate systems. Nobody can say, with evidence, whether an area is ready to run.
Disconnected EAM, historian and permit tools allow work orders to release without parts at workface or verified isolations.
Inspect System FeedsOne evidence chain links every asset, control, resource and decision from pit to port, so a defect is traced to its production and margin consequence.
Couples MinePlanPeriod ore hardness, FlowsheetStage bottlenecks, SparePart lead times, and IEC 61511 / GISTM TARP barriers.
Open Resource Value ChainRelease, restart and intervention decisions are made against explicit criteria, approved by named owners, and checked against what actually happened.
48-hour post-maintenance telemetry stabilization and independent verifier sign-off feed directly into the Brier Trust Center.
Open Brier Trust CenterInteractive Pit-to-Port Constraint & Cascade Simulator
Click any stage along the resource value chain to trace how a local asset or control defect cascades into downstream margin exposure.
SAG mill shell liner wear & pinion vibration (5.8 mm/s RMS) on harder BWI 18.4 ore
Stage 3: Grinding (Binding constraint)
Zero intermediate buffer — every hour of unplanned SAG downtime directly loses 1,250 t of plant throughput.
Survive-to-Shutdown 6% feed derating bridge to planned 96h reline window
One event, start to finish (90-Second Closed-Loop Walkthrough)
Illustrative walkthrough using Generic demonstration records across the 5-step engineering decision loop.
Continuous telemetry flags a sustained vibration excursion on DEMO-SAG-101 coinciding with a Pit Stage 4 shift to harder ore (Bond Work Index 18.4 kWh/t).
Platform Evidence Basis
Sensor PI-VIB-101A · 5.8 mm/s RMS (Alarm: 4.5) · Freshness: 4 min ago
Governed Step Output
Finding raised with measured telemetry & feed-hardness correlation
02
Part 02
Evidence-backed gates that confirm people, materials, isolations and approvals before work is released or plant is restarted.
Operational readiness, full lifecycle
The same governed Go/No-Go discipline applies across all nine asset lifecycle stages—coupling live supply-chain ETAs, SIL barrier status, PSSR isolations and 48-hour post-startup telemetry stabilization.
Interactive 9-Stage Lifecycle Gate Explorer
Select any operating lifecycle stage to inspect its mandatory gate criteria and live signal coupling.
Concentrator 96-Hour Major Shutdown & Mill Reline
Site Turnaround Governance Standard · Critical Path Lock
All path-critical materials at workface 72h prior; crane & reline crew reservations confirmed.
$1.45M/day concentrate netback loss for every 24h turnaround overrun
Interactive Gate Decision Simulator
Click any requirement below to toggle its evidence state and see how the Readiness Gate enforces release discipline.
1. Four-Dimension Evidence Inputs (Click to toggle)
Governed Release Gate
HOLD · 2 BLOCKERS
Startup and work execution are locked. Non-waivable safety, workface material, or competency gaps cannot be overridden.
2. Accountable Execution & Handover
1. Controlled Release & Startup
Locked until all non-waivable blockers are cleared.
2. 48-Hour Telemetry Stabilization
Post-startup vibration, temperature, and process flow are audited against acceptance criteria before closure.
3. Receiver Handover & Ledger Proof
Operations Receiver signs handover acceptance; verified avoided downtime posts to the Savings Ledger.
One controlled record per system, operating duty and window—with named owner, approver, verifier and revision basis.
Mandatory safety, statutory, technical and production items cannot be marked ready without independently reviewed evidence.
Phase-by-phase mechanical, energisation, wet commissioning and performance gates that hold release on open Category-A punch items.
Automatically links Purchase Order arrival dates and IEC 61511 SIL barrier health so late spares or bypassed trips block premature release.
High-risk licence verification, material staging to the workface and time-window crew reservations that prevent double-booking.
Handover acceptance requires 48 hours of post-startup vibration, temperature and flow telemetry within baseline limits before posting verified savings.
03
Part 03
One decision loop from project handover through operation, maintenance, turnaround and closure, with every outcome verified.
Operating lifecycle × 5-step decision loop
Each lifecycle stage follows the same discipline: detect, diagnose, decide, execute and verify. Select any stage below to inspect its closed-loop workflow and linked platform modules.
Lifecycle Stage 01
Is the new system proven ready to receive load?
Active Platform Modules
1 · Detect
Open punch items, incomplete tests and missing vendor documentation per area, subsystem and asset.
2 · Diagnose
Separate release blockers from handover blockers and advisory items against each acceptance criterion.
3 · Decide
Phase gate approvals from mechanical completion through energisation, wet and performance testing.
4 · Execute
Owners close tests and punch items with retained evidence; O&M manuals populate spares and schedules.
5 · Verify
Receiver accepts handover only when every mandatory test and blocker is closed and reviewed.
Executive decision governance
A closed-loop decision ledger preserves accountable approval, traceable evidence, execution timing and measurable production or financial outcomes. Select any stage to inspect its governed record structure.
DEMO-SAG-101 pinion vibration 5.8 mm/s RMS on harder Pit Stage 4 ore (BWI 18.4 kWh/t) — $68,500/hr constraint margin at stake.
Every transition requires named role attribution and timestamped evidence; self-approval on verification is blocked by platform policy.
04
Part 04
The modules, sector coverage and controls that support readiness and lifecycle decisions.
Inside the platform · Interactive Workspace Sandbox
Readiness passport · DEMO — SAG mill reline & drive overhaul
Turnaround · HOLD — 2 mandatory blocker(s) preventing release
Safety & statutory
2/2
Gate ReadyTechnical
1/1
Gate ReadyExecution
0/2
Blocker OpenProduction
1/1
Gate ReadyInteractive preview: click any requirement row above to simulate clearing or raising a workface blocker.
Integrated operating model
Model extraction, processing, stockpiles, utilities and logistics as one capacity-constrained production chain.
FlowsheetStage · CommodityProfile · ResourceNode
Pinpoints the active bottleneck and computes $/hr margin exposure across series and parallel nodes.
Open workspaceConnect plant, fleet, scans, condition and spatial context to the assets and stages that drive production.
Equipment · LiDARScan · ConditionReport
Open workspacePrioritise preventive, predictive and corrective work by failure consequence, production exposure and readiness.
FailureMode · WorkOrder · ManualMaintenanceRule
Open workspaceAlign maintenance windows, technician capacity, critical spares and production constraints before releasing work.
TurnaroundScope · ReadinessPassport · SparePart
Open workspaceTranslate lost tonnes, downtime, energy, reliability and risk into margin exposure and capital priorities.
SavingsLedgerEntry · CapitalPlanItem · OreMarginAssessment
Open workspaceControl projects, shutdowns, budgets, risks, dependencies, sign-offs and realised operational benefits.
Project · CapitalPlanItem · IntelligenceDecision
Open workspaceCapture inspections, defects, evidence and shift actions at the point of work, including mobile workflows.
InspectionRound · ShiftHandover · VoiceFindingCapture
Open workspaceMonitor production, geotechnical, tailings and compliance controls with accountable escalation and audit history.
SafetyCriticalElement · SafetyInstrumentedFunction · TARPlan
Open workspaceResources-sector coverage
Select any sector domain below to inspect the asset classes, governing engineering standards, and live workspaces unified by AssetStack.
Covered Asset Classes · Mining & quarrying (Open-pit & Underground)
Governing Engineering & Statutory Basis
ISO 55001 · Geotechnical TARP · Statutory Mine Safety Regulations
Enterprise operating control
Every operating area shares the same flowsheet, asset, economic and control context so leaders can act on cross-functional consequences rather than isolated reports.
Expose the system bottleneck, quantify lost throughput and focus action on the stage limiting saleable output.
Compare availability, utilisation, payload, component life and cost per tonne across the mobile fleet.
Connect spares, supplier lead times and component change-out windows to production continuity.
Link energy intensity, cost and emissions to production while ranking practical abatement investments.
Benchmark operating sites, expose structural performance gaps and transfer repeatable practices.
Surface emerging constraints, recurring losses, control gaps and unrealised value across the portfolio.
Interrogate operational evidence, explain value at stake and prepare governed actions in plain language.
Unify production, risk, readiness, decisions and financial exposure into one executive operating picture.
Why it stands apart
Condition, production, controls, spares, energy and capital share one record, so a number always shows where it came from and what it affects.
Status Quo Gap: Traditional stack: Vibration sits in APM, work orders in EAM, stockpile hours in spreadsheets, and TARPs in EHS folders.
AssetStack traces SensorReading → FailureMode → FlowsheetStage $/hr → SparePart ETA → ReadinessPassport in one graph.
Every recommendation carries alternatives, assumptions, confidence and an accountable approver, and stays open until its result is verified.
Status Quo Gap: Traditional stack: Alerts are closed when acknowledged, and work orders close when the wrench stops turning—whether the defect recurred or not.
IntelligenceDecision enforces separation of duties between proposer, approver, and post-intervention outcome verifier.
Work is ranked by production and margin exposure and safety consequence, not by asset condition alone.
Status Quo Gap: Traditional stack: A critical pump on a redundant standby train gets the same priority as a single-point failure starving the SAG mill.
Ranks every action by series/parallel redundancy, surge buffer hours, payable metal netback, and SIL/TARP barrier impact.
Predictions are scored against verified outcomes in the Trust Center, and confidence is calibrated from that record.
Status Quo Gap: Traditional stack: Black-box models emit uncalibrated risk scores with no feedback loop when field inspections prove them wrong.
Continuous Brier score decomposition and Empirical Bayes prior recalibration across 28+ verified ground-truth outcomes.
Sector-wide competitive benchmark
Mining and resources operators typically buy an EAM for work orders, an APM for sensor alerts, a mine-planning tool for block schedules, and a safety tool for permits and TARPs. Because none of them shares an evidence chain or a readiness gate, the critical trade-offs between geology, reliability, safety barriers and margin happen in spreadsheets. AssetStack unifies the entire decision loop—and feeds directly from existing EAM and historian investments rather than requiring a rip-and-replace.
| Operating capability | AssetStackClosed-loop decision OS | Legacy EAM / ERPSAP S/4 PM · Maximo · Ellipse | Standalone APMGE Vernova · AVEVA · Mtell | Mine Plan & Safety Point ToolsHxGN · Deswik · Sphera · Seequent |
|---|---|---|---|---|
Mine-to-Mill ore hardness & abrasion coupling Planned Bond Work Index (kWh/t) and Abrasion Index dynamically shift Weibull failure windows and liner/wet-end wear forecasts. | Full native Native MinePlanPeriod → Weibull RUL & wear coupling | Absent No geology or ore-hardness awareness | Absent Reads historian tags without mine-plan feed context | Siloed / partial Schedules blocks & blends; stops at crusher dump pocket |
Survive-to-Shutdown dynamic derating optimizer Solves the exact throughput/load derating curve required to stretch a degrading asset safely to the next planned turnaround. | Full native Physics-coupled stress ratio & margin trade-off solver | Absent Static work order dates only | Siloed / partial Raises anomaly alerts; does not solve derating vs margin | Absent Outside scope |
Flowsheet bottleneck & stockpile buffer $/hr economics Traces every defect through series/parallel redundancy, surge stockpile hours and payable commodity netback to exact $/hr at stake. | Full native Live FlowsheetStage + CommodityProfile margin engine | Absent Tracks maintenance cost, not lost production margin | Siloed / partial Static criticality scores without live buffer depletion | Siloed / partial Models haulage tonnages, not downstream plant bottlenecks |
Pit-to-port & well-to-terminal resource value chain Unifies open-pit/underground mining, mineral processing, rail, port shiploaders, pipelines, water and power in one dependency graph. | Full native Cross-corridor ResourceNode outage & buffer simulation | Siloed / partial Stores asset hierarchy without corridor flow simulation | Siloed / partial Monitors individual rotating equipment tags | Siloed / partial Focused on pit/underground; blind to rail, port & utilities |
Hard-gated Operational Readiness Passports Blocks work release or plant restart until materials at workface, verified competencies, LOTO isolations, PSSR and dependencies pass. | Full native Enforced release gate across project, outage & daily work | Siloed / partial Tracks work status; permits premature release without proof | Absent No work execution or readiness gating | Siloed / partial Permit-to-work forms disconnected from spares & RUL |
IEC 61511 SIF PFDavg & GISTM Tailings TARP co-optimization Computes live safety-loop PFDavg from proof-test intervals alongside piezometric/radar TARP levels and pressure integrity. | Full native Joint SIL proof-test, TARP & pressure derating solver | Absent Treats proof tests as generic calendar tasks | Siloed / partial Basic SIS tracking without geotechnical TARP coupling | Siloed / partial Separate bow-tie or radar tools that never talk to plant ops |
Supply-chain lead-time vs RUL stockout collision Flags every critical spare whose supplier lead time exceeds the asset’s predicted failure window and drafts expedited procurement decisions. | Full native Automated BOM-to-Weibull window collision & PO drafting | Siloed / partial Min/max reorder points blind to live asset degradation | Absent No inventory reservation or supplier lead-time engine | Absent Outside scope |
Opportunistic shutdown scope bundler When an unplanned stop or shadow window opens, ranks ready-to-execute secondary scopes by avoided future downtime per hour. | Full native Knapsack solver constrained by trades, crane & spares ready | Absent Manual backlog filtering during outages | Absent No turnaround craft or readiness constraints | Absent Outside scope |
Verbatim O&M manual-to-governed maintenance programme Extracts intervals, tolerances and condition limits with exact page excerpts, requires engineer applicability sign-off, and governs revisions. | Full native Page-cited extraction → approved rule → verified occurrence | Absent Manual data entry of task lists; PDFs sit in attachments | Absent Rules hand-coded by data scientists without OEM citations | Absent Document control without automated rule synthesis |
Cross-site Empirical Bayes cohort survival transfer Transfers Weibull shape/scale priors across sister assets and sites, weighting by operating duty and slurry/environment severity. | Full native Portfolio-wide Bayesian survival transfer across sister units | Absent Site-siloed work histories | Siloed / partial Single-asset ML models trained per tag | Absent Outside scope |
Accountable decision ledger with post-work verification Every material action records alternatives, assumptions, accountable role and SLA, and remains open until physical post-work proof passes. | Full native DETECT → DIAGNOSE → DECIDE → EXECUTE → VERIFY loop | Absent Closes work order on wrench completion, not outcome proof | Absent Closes alert when acknowledged | Siloed / partial CAPA tracking without production or reliability feedback |
Brier-calibrated Trust Center & independent Value Proof Scores every forecast against ground truth, recalibrates model priors automatically, and forbids self-approval on claimed savings. | Full native Live Brier decomposition, reliability curves & public scorecard | Absent No prediction accuracy tracking | Absent Vendor-claimed ROI; no self-scoring Brier ledger | Absent Outside scope |
05
Part 05
How the platform is introduced, scaled and governed across sites.
Transparent economic model · Exposed constants
Hourly bottleneck margin exposure
$67,500 / hr
Annual unplanned exposure
$6,480,000 / yr
1. Avoided constraint downtime (25%)
$1,620,000
2. Opportunistic shutdown scope bundling (6h eq.)
$405,000
Estimated annual margin protected
$2,025,000
09 · Deployment
A staged rollout that proves value on real constraints before it scales.
Weeks 1–2
Load the asset register, flowsheet and priority feeds for one site. Demonstration records are clearly labelled until site data replaces them.
Gate 1: Asset hierarchy, flowsheet stages, and historian/EAM connector mappings verified.
Inspect workspaceWeeks 3–6
Run the decision loop on a defined set of constraints. Each decision carries an accountable role and acceptance criteria.
Gate 2: Live constraint & RUL proposals routed through Decision Room with named owners.
Inspect workspaceWeeks 7–12
Measure outcomes against acceptance criteria and record verified value in the savings ledger.
Gate 3: Post-intervention 48h stabilization audited and signed off by independent verifier.
Inspect workspaceBeyond
Extend to further sites, rail, port, water and power assets, with cross-site benchmarking.
Gate 4: Multi-site Empirical Bayes cohort survival transfer and Executive Board Pack live.
Inspect workspace10 · Engagement model
Commercial terms are scoped to the operation. Every stage has agreed success criteria.
One site, one value chain, fixed scope and success criteria agreed before start.
90-day fixed validation · 1 bottleneck circuit · Full readiness & ledger access
Full workspace coverage for an operating site, integrated with existing systems of record.
Mine-to-Port flowsheet · Automated EAM/PI feeds · Unlimited Readiness Passports
Multi-site portfolio, governance policies, single sign-on and cross-site benchmarking.
Cross-site Weibull transfer · Portfolio Board Pack · Role-governed RLS & SSO
Straight answers
"Our data is not clean."
Start with what you have. Import and readiness checks show which records are missing or stale, and every finding is labelled measured, calculated, estimated or stale.
Pre-mapped connector presets for AVEVA PI, SAP S/4 PM, Maximo, Ellipse, Cat MineStar and GISTM TARP feeds validate schema mapping and staleness automatically.
"Can we trust the recommendations?"
Each recommendation shows its source records, assumptions and confidence. Material decisions go to an accountable person for approval, with an audit trail and a recorded verification.
Every forecast is tracked in PredictionAccuracy against field truth (92.9% hit rate, 0.034 Brier score) and recalibrated via Empirical Bayes.
"What about security and IT fit?"
Access is role-based and sign-in is required for all operating pages. Ingestion supports session-based access for people and controlled endpoints for systems. Data location and integration scope are agreed in the pilot.
Row-level security (RLS), immutable audit logging, and separation of duties between proposer, approver, and independent verifier.
"How long until value?"
A scoped pilot on one site and one circuit, with success measures agreed before start. Day-30 baseline, Day-60 live decision queue, Day-90 verified ledger outcome.
Savings are only recognized as board-reportable after 48-hour post-maintenance telemetry stabilization and independent verifier sign-off.
The next step · 90-Day Pilot Blueprint
Proposed 30/60/90-day governance milestones. Click any phase to inspect its deliverables and live platform workspace.
Days 1–30
Phase 01Connect, ingest & baseline
Days 31–60
Phase 02Enforce Readiness Gates & rank work
Days 61–90
Phase 03Verify 48h outcomes & prove ledger value
Enter the Command Center
Move from fragmented functional reports to a governed resources operating picture with accountable action and verified value.