Put your best performance on repeat, every time

Managing a fleet means juggling many issues: scheduling equipment, keeping an eye on material movement and tracking fuel use and cycle times. Where to start? Minestar™ FLEET.

Our Fleet Management Technology solutions will help you master control of your mine fleet. FLEET analyses operational and equipment data and gives you insights into your fleet to offer a big-picture solution. You can analyse and replicate what’s working, and fix what’s not.

FLEET has real-time dashboards with custom reporting to always deliver accurate information suited to your load/haul system.

No matter where you are on-site, FLEET gives pit supervisors in-depth insight into all aspects on mine operation. Check daily progress goals during the shift – not just after. Track machine locations, speeds, payloads and fault codes in real time.

Manage your fleet with real-time notification of bottlenecks, machine issues and identification of trouble sites and make immediate adjustments. Make more effective use of time thanks to faster decision making based on accurate, real-time information.

Improving productivity wherever you are

A fleet management solution that suits any sized operation, Minestar FLEET will improve productivity, save money and help you monitor your fleet through a mobile tablet device on a low-bandwidth, cloud-based operation.

Key cost drivers are delivered when you need them: including operator assignments, breaks and shift changes along with fuel usage and machine idle times. FLEET works with any brand of equipment and you can share data across your existing machines and mine management solutions. It’s that simple.

MineStar Reporting

MineStar Reporting is a revolutionary data visualisation and reporting tool focused on integrating data gathered from other Cat MineStar solutions and consolidating it into a single, unified interface.

MineStar Reporting is currently available to any mining organisation using FLEET.

FLEET capability packages

FLEET is a flexible solution that can be customised and configured based on your mine’s specific operational requirements. We offer five capability packages within FLEET. These packages are outlined below.

Available packages:

1. Production – Delivers real-time visibility of production operations, improved shovel loading performance, and increased payload predictability.
2. Position & Material – Monitors material movement, alerts operators and planners of misroutes, monitors machine location, and incorporates playback function to analyse dump movement and road congestion.
3. Assignment & Optimisation – Schedules and assigns trucks, maximises utilisation and production, minimises truck wait time, and manages shift changes.
4. Data Share – Enables Fleet to share data and information with other electronic mine management systems so you can easily see what’s going on with your fleet.
5. Multi-Site – Enables the management of multiple Fleet-equipped mine sites from a single control centre.

If you manage a small mining operation or quarry, and the packages above are not suitable, we also offer MineStar EDGE.

Need a simpler option? minestar edge

PLAN THE DIG, DIG THE PLAN

For mining accuracy and efficiency, you need an integrated system that works no matter where you are. You need tools that give your operators the confidence they need to work more precisely and productively, regardless of how tough the terrain is. You want technology that allows you to quickly replicate successes and correct inefficiencies. Terrain is the earthmoving solution that will give you all of this and more.

To put it simply – there are thousands of ways to manage a dig. Minestar Terrain helps you find the most effective one. A commander wouldn’t send troops into battle without understanding the best method of attack, why would you send your operators into a mine without understanding the most effective dig plan?

No matter your operational needs are, Terrain has the right solution to change your business landscape, all thanks to CAES (Computer Aided Earthmoving Systems).

In addition to providing technology, our Solutions team provides a number of tailored dig planning services that may involve a combination of the technologies listed below, in addition to some of our other services.

MineStar Reporting

MineStar Reporting is a revolutionary data visualisation and reporting tool focused on integrating data gathered from other Cat MineStar solutions and consolidating it into a single, unified interface.

MineStar Reporting is currently available to any mining organisation using TERRAIN.

Terrain for Grading

send your team home safe, every day

Mining equipment is large, and space is often tight, reducing visibility in critical areas. Incidents and accidents due to operator error or oversight can be dangerous and costly, but there is a solution to help boost awareness of what’s happening on your mine site.

Increase your operation’s vigilance with Cat Minestar Detect: a solution that helps you see more on the job. You want to keep your team safe – we offer technology that allows you to do this; technology that gives you line-of-sight to a safer and more efficient operation. Detect can be fitted to any machine, from any manufacturer, to give you a better view of what’s happening on your site.

Whether you need satellite capabilities to deliver proximity warnings and highlight avoidance zones, or fatigue or distraction detection, Detect has the technology to enhance machine safety on your site.

Advanced object detection alert system

If your space is tight, or you have multiple trucks operating in the same area, collision avoidance systems are one of mining’s most crucial safety systems. Our object detection systems add an extra layer of operator visibility, allowing for visual and sensor checks to give your operator peace of mind.

No matter how alert your operator, there are blind spots that can lead to incidents and accidents. Cat Object Detection automatically detects and alerts operators to potential hazards in front, behind or near the machine.

Fatigue & Distraction Management

With optimised radar and camera coverage and audible warnings, MineStar Detect offers configurable operations tailored to your site or fleet. You can control your costs by reducing accidents and limiting machine damage and lost time by preventing collisions between vehicles and objects.

No operation is immune to fatigue and distraction, particularly when tasks are repetitive. To give you peace of mind Cat Detect offers Fatigue and Distraction Management, a technology to help you build a culture that puts safety first.

Our in-cab cameras monitor facial expressions and provide alerts when drivers show signs of drowsiness. When combined with a Fatigue Management System that encourages healthy nutrition and quality sleep at home, you can fight fatigue with a multi-level approach.

MineStar Detect Technology Options

• Detect Vision – Camera
• Detect Object Detection – Radar
• Detect Proximity Awareness – GNSS & P2P
• Detect Driver Safety System (DSS)
• Detect for Personnel (CDP) Detect DVR

Health Benefits

• Boost machine availability
• Reduce unplanned downtime
• Prevent costly failures
• Make informed decisions
• Track performance

Healthy equipment = lower costs

You plan for everything in your operation, but what about unexpected setbacks? Breakdowns, unexpected repairs or equipment that’s just not running to standard can really impact on your bottom line.

Nobody wants downtime in a project, or costly repairs that can set your budget back. Like a Doctor, Cat Health is a consistent check up for your equipment to diagnose and identify issues before they’re a (costly) problem.

Our real-time equipment monitoring technology tracks and records a range of machine parameters for ongoing fleet health. You can also customise reports to track when services are due, schedule any repairs and monitor your fleet’s post-repair performance.

With Minestar Health, your service team will get instant alerts when problems arise, ensuring that you can take immediate action to have your machines repaired quickly and back to making money in no time.

Take advantage of a Global Knowledge Sharing network with field-tested best practice and fleet performance insights. You can assure your fleet’s health by leveraging the power of Cat experts from around the globe. They’ve been there, done that, so you can learn from their knowledge.

Sharing information and data easily

As part of the Cat Minestar System, Health shares data with other Cat Minestar Systems, ensuring that you can track, monitor and manage all types of assets more safely, efficiently and productively.

Health works with on-board monitoring systems such as VIMS (Vital Information Management Systems) to provide real-time, wireless data and reports. Protect your investment with our technology solutions.

Identifying health hot spots

No matter your equipment’s brand, Cat Health can help you track its health. We give you the inside information you need to keep your equipment in tip-top shape. But it’s not just your machines’ health that’s monitored. Health can also help you identify any problem areas in the mine site where health and operational alerts occur.

MineStar Reporting

MineStar Reporting is a revolutionary data visualisation and reporting tool focused on integrating data gathered from other Cat MineStar solutions and consolidating it into a single, unified interface.

MineStar Reporting is currently available to any mining organisation using HEALTH.

AUTOMATION FOR THE MINING INDUSTRY

Whether your mining operation is big or small, above or below ground, your priority is to safeguard your people, ensure your operation is efficient and keep your equipment running smoothly. Whatever your operational challenges are, WesTrac can deliver an automation solution to overcome them.

It’s no secret that automation technology boosts productivity, reduces overall costs, improves efficiency and increases profitability. Aside from these benefits, it will open up new opportunities for your business. Whether it’s automating a single mining process or implementing a fully autonomous fleet of hauling trucks, this technology will give you an edge over competitors and make everyday easy.

Take control of your operation

MineStar Command is a flexible and customisable technology that helps you take control of your operation. You choose the level of automation that’s right for your site – from operator assistance right through to full autonomy.

No two operations are alike, so Command gives you the capability to adapt what’s working elsewhere to suit your site-specific needs. Autonomous drilling, underground mining, hauling, or dozing – whatever your needs, there is a MineStar Command automation solution that will help you achieve your goals.

The real-word benefits of MineStar Command also help reduce overall costs while improving productivity, addressing the skills crisis and expanding your options.

Tailored Automation Services

In addition to providing technology, our Mining Solutions Team provides a number of tailored automation services that may involve a combination of the technologies listed above, in addition to some of our other services.

This could involve our team automating one or more of your operation’s mining processes, end-to-end. It might also be that your operation is better suited to a semi-autonomous solution.

MineStar Reporting

MineStar Reporting is a revolutionary data visualisation and reporting tool focused on integrating data gathered from other Cat MineStar solutions and consolidating it into a single, unified interface.

MineStar Reporting is currently available to any mining organisation using COMMAND.

Command for Hauling

Cat® MineStar Command for hauling has forever changed how mining companies move material – allowing them to haul more efficiently with near-continuous operation and move more with fewer people on site. Proven on diverse operations around the globe, Command for hauling is opening new possibilities for mines of all sizes, complexities and locations. Command leverages other MineStar capabilities to provide the fully integrated operation of remote control, semi-autonomous and fully autonomous mining systems. Autonomous trucks operate safely around other equipment, light vehicles and personnel. Command trucks respond to calls to the shovel, move into position, haul to dump points and even report for maintenance – all without an operator on board.

Command for Hauling Benefits

• Enhances safety by removing operators from hazardous or remote sites.
• Reduces costs for employee infrastructure and travel to remote sites.
• Improves efficiency, enables consistency in operations and provides near-continuous operation through the reduction of operational delays – eliminating daily operator breaks (lunch and breaks), allowing hot seating, reducing queuing times, allowing machines to run in inclement weather, etc.
• Improves fuel efficiency and component life.
• Prevents machine damage and downtime due to misuse and overloading.
• Allows the instant alteration or redesign of mine maps to meet changing operational needs.
• Enables advanced assignment and tracking from a central location.
• Alerts maintenance personnel to machine faults, enabling repairs before failure and reducing downtime.
• Allows mines to attract new employees with a safe, comfortable work environment close to home.
• Extends careers by upgrading skills and reducing exposure to hazards.

What makes Cat MineStar for Hauling different?

• Interoperability: While putting Cat technology on Cat equipment is the ideal scenario, Command for hauling is not limited to Cat machines. Caterpillar will partner with customers to develop Command technology on other OEM brands.
• Integration: MineStar offerings make up a fully integrated system.
• Smarter Trucks: Trucks with Command for hauling have electronics on board, giving them the ability to think for themselves for a more robust autonomous system.
• Advanced Perception System: This system allows trucks to run at full speed and can also be used to survey load and dump areas, providing a Rate of Production advantage. Competitive systems may provide similar utilization improvements, but it’s the work done or “Rate of Productivity” that is a key differentiator.
• Defensive Driving: The system anticipates manned behavior to slow down or stop due to intersecting paths.
• Multiple Truck Dumping: Command allows multiple trucks to enter and dump simultaneously.
• Crusher Dumping: Command allows autonomous trucks to tip automatically.

Command for Drilling

Cat® MineStar Command for drilling ensures that every hole is accurately placed, drilled to the proper depth and angle, and able to stand up until blasting. A range of capabilities lets site managers configure and automate the drilling system to their budgets and needs.

Semi-autonomous single row drilling automates the entire drilling cycle for one row, including autonomous tramming.

Autonomous pattern drilling automates drill cycles and tramming for the entire blast pattern and allows one operator to manage drill operations across the mine site from a remote operator station.

Command for Drilling Benefits

• Enhances fragmentation consistency by precisely executing drill patterns.
• Ensures accurate hole placement – to the right location and hole depth.
• Ensures better-shot material, which means smoother downstream operations.
• Allows removal of operators from dust and other hazards.
• Improves operator comfort, recruitment and retention.
• Simplifies training to make new operators productive more quickly.
• Through improved consistency, reduces the costs associated with fuel, drill tools and explosives.
• Improves equipment utilization, productivity and operator effectiveness.
• Allows adjustment of collar elevations on uneven ground to ensure consistent toe elevations.
• Reduces hole-to-hole tramming time.
• Preserves machine life and reduces GET tool waste by limiting operation to be within the OEM parameters for both the machine and the drill tools.
• Enables consistent drilling from operator to operator on any terrain.

What makes Cat MineStar for drilling different?

• Integration: MineStar is a fully integrated system between Fleet, Terrain, Detect, Health and Command.
• Interoperability: While putting Cat technology on Cat equipment is the ideal scenario, Command for drilling is not limited to Cat machines. Command for drilling is interoperable with multiple brands of drills.
• Scalability: Command for drilling follows a building block approach – from Operator Mission Assist to Semi-Autonomous to Fully Autonomous – which allows sites to adopt automated drilling at different levels. This approach is unique to the industry.

What can you expect with Cat MineStar for Drilling?

MineStar Command for drilling is proven to deliver a 34 percent improvement in production versus a manned operation and a 20 percent reduction in OPEX cost per meter drilled.

THE LEADING EDGE OF AUTONOMY

Mount Pleasant coal mine is a complex coal deposit located in New South Wales, Australia, owned by MACH Energy. Characterised by high quality coals, a low strip ratio and high-processing yield, Mount Pleasant contains some of the most attractive coal resources in the Hunter Valley.

A team of innovators from Caterpillar, WesTrac and Thiess find the site attractive for another reason: It’s an ideal proving ground for drilling autonomy. Leveraging Cat MineStar Command for drilling on a fleet of Cat MD6250 rotary drills, the three entities have found the greenfield site and its complex drilling conditions the perfect stage to explore autonomous operations. Working together, they are adding value to the Mount Pleasant operation while setting the stage for the sustainable mine of the future.

In this video below, Thiess and WesTrac representatives showcase autonomous drilling, discuss the breadth of Caterpillar’s other Command autonomous solutions, and share their enthusiasm about being on the leading edge of autonomous technology.

Command for Dozing

Cat® MineStar Command for dozing improves safety and efficiency by taking operators off their machines and letting them work from either nearby or remote locations.

Command delivers value across the entire operation through consistent dozing, increased safety, greater operational efficiency, reduced operational waste and lower costs.

Deep integration with Cat machine systems enables smooth, precise control for maximum efficiency and productivity.

The system is scalable and flexible, with three modes of operation.

An over-the shoulder, portable console works well for short duration activities.

A remote operator station enables the operator to work in a comfortable, seated position with familiar controls. And semi-autonomous operation allows a single operator to manage multiple machines for maximum efficiency.

Command for Dozing Benefits

• Protects operators from on-site dangers and environmental hazards.
• Eliminates prolonged exposure to noise, dust and vibration.
• Allows application of geo-fencing and Avoidance Zone capabilities from Cat MineStar Terrain.
• Enables operations from a comfortable off-site command center close to home.
• Reduces travel costs and infrastructure needs
• Improves equipment utilization and shift-long operator efficiency.
• Provides a range of Command for Dozing offerings to suit the needs of individual sites and applications.
• Improves productivity and efficiency by making it possible for one operator to control multiple dozers.

What makes Cat MineStar for Dozing different?

• Integration: MineStar is a fully integrated system, and Command for dozing is deeply integrated with the machine systems on Cat dozers for maximum efficiency.
• Semi-autonomy: Command for Dozing is the only semi-autonomous dozer product available in the mining industry.

What can you expect with Cat MineStar for Dozing?

• 15% Productivity Improvement
• 40% Reduction in Operational Waste
• $0.02-$0.05 Reduction in Cost Per Yard

Australian Success Story

Cat MineStar Command for Dozing has proven results at a number of sites and production studies have shown significant opportunities. WesTrac partners with customers to get real-world feedback about how the system is performing and we use that feedback to continually improve the product and processes.

Recently, an Australian mining site fully implemented semi-autonomy, equipping seven dozers and netting $2 million per year in increased profit thanks to an increased production gain of 3 million bank cubic meters annually.

Command for Underground

Cat® MineStar Command for underground relocates operators to a safe, comfortable operating station on the surface. That improves utilisation by reducing the last-to-first-bucket time during shift changes. It all adds up to more material moved and more profit for your mine’s bottom line.

Command for Underground Benefits

• RELOCATE operators to a safe, comfortable location underground or on the surface.
• ENABLE control of multiple machines from a single Remote Operator Station.
• ELIMINATE exposure to noise, dust, seismic activity and other underground hazards.
• PREVENT collision damage caused by LHD machines contacting tunnel walls.
• OPTIMISE shift changes by enabling hot-seat operator exchanges on the surface.
• RETURN to work quickly after a blast to get production back on track.
• IMPROVE operator comfort, employee retention and operator recruitment.
• MONITOR operations through video, with real-time location and status date.
• CONFIGURE zones to regulate machine speed to establish exclusion areas.
• CONTINUE operation through seismic events.

Understanding the Cat MineStar for Underground LHD Systems

• Line-of-Site Remote Control Loading – A portable controller lets operators work from a safe distance while the machine loads under an unsupported roof.
• Remote + Guidance Operation – An advanced Remote Operator Station enables control from the surface or an off-site location. Basic system remotely controls load, tram and dump functions. A guidance upgrade supplements steering to minimize drive wall impacts.
• Semi-Autonomous Operation Copilot Mode – Operators monitor machine location on a mine map as they load, tram and dump, providing directional input using joysticks. Autopilot Mode – allows the machine to tram, dump and return autonomously. The operator then takes control of the loading process.
• Autonomous Operation – Combining auto dig functionality with Autopilot Mode provides completely autonomous Load-Haul-Dump cycles.

MineStar Command for Underground is a gamechanger

In late 2020, Caterpillar MineStar Command for Underground was announced as Tasmania’s top Engineering Excellence Award winner and Sir William Hudson Award finalist. The winner is a ‘game changer’ for people with disabilities.

An operational ecosystem for your surface mine

What if you could use proven Cat® MineStar™ technologies across you entire mining organisation and have visibility to every aspect of your operation? What if you had near-real-time access to data that was up to 98% accurate? And what if you could make changes in-shift while already knowing the impact they would have further down the value chain?

With Cat MineStar EDGE, you can.

What is Cat MineStar Edge?

MineStar EDGE is a new technology platform designed for smaller mining operations and quarries. EDGE provides many of the fleet management capabilities of MineStar FLEET, via a simpler, lower-cost, cloud-based system with easy-to-install onboard hardware.

EDGE creates an operational ecosystem that gives you visibility to every aspect of your operation, allowing you to efficiently execute your mine plan and deliver optimal quality to the plant and to the surface.

MineStar EDGE makes it possible to measure, manage, analyse and optimise your entire operation. And because it’s delivered as a cloud-based, subscription-managed application, it lowers costs and delivers a better user experience.

MineStar Edge Features and Benefits?

MineStar EDGE:

• gathers SMU data continuously from ALL assets (not just Cat brand)
• delivers high-accuracy data recording, reducing downstream errors
• provides the ability to replay shifts in great detail (useful for investigations)
• records when equipment is available, down, operating or stopped
• measures time when equipment is not productive and applies machine-learning
• classifies downtime as scheduled or unscheduled
• allows you to better manage/measure operators by tracking performance
• helps improve equipment availability, reliability and production

Is Cat MineStar EDGE suitable for my operation?

Cat MineStar is a solution designed for larger mining organisations with big fleets. Before EDGE, there wasn’t a comparable solution for smaller operators and quarries, which meant they were missing out on all the benefits that come with a comprehensive mine operations system. Until now.

EDGE provides a way for smaller operators to access the benefits that come with digital equipment tracking and production recording, at a cost that works for them.

EDGE is suitable for mining organisations or quarries, with small-to-medium size fleets, who are still relying on paper in one or more operational areas, i.e. paper-based reports, time cards and incident tracking.

Is Cat MineStar Edge scalable?

Yes, EDGE is a fully scalable solution that allows you to add functionality as your operation grows in size. With EDGE, you only pay for what you need.

How do I get MineStar Edge?

To begin accessing all the benefits that come with EDGE, you’ll need to get in touch with our Technology Team.

All your data. all in one place. all the time.

No matter which Cat® MineStar™ technologies you use, your mine is constantly generating data — every machine, every cycle, every second. It helps you to make better decisions and optimise your planning, productivity, maintenance and more. But that amount of data can be intimidating, especially when it’s gathered and reported by multiple systems using different interfaces.

What if you could access all your data in one place? What if you could view reports from multiple technology solutions simultaneously — all in one clean, intuitive and easy-to use interface?

With Cat MineStar Reporting, you can.

What is Cat MineStar Reporting?

MineStar Reporting is a revolutionary data visualisation and reporting tool focused on integrating data gathered from other Cat MineStar solutions and consolidating it into a single, unified interface.

Historically, each Cat MineStar technology gathered and presented its data using custom reporting tools specific to that capability — FLEET data is presented one way, while TERRAIN data looks completely different. Some solutions could be extended, others could not.

MineStar Reporting integrates the data gathered by your MineStar technologies — and even systems provided by other vendors — into a comprehensive database that can be accessed on any web-enabled device. You can create custom dashboards designed to put the right data in the right hands, and create automated email reports to ensure all data is received at the right time. And since all data is housed in a single repository independent of any one solution, you don’t risk losing valuable historical data when you update or change your technology systems.

It’s a flexible, scalable solution that allows you to simplify reporting of the data you currently gather while leaving space open for future solutions when you’re ready to adopt new technologies. The solution also offers upgrades to connect other mining data sources for more comprehensive analysis.

MineStar Reporting is currently available for FLEET, HEALTH, COMMAND and TERRAIN, and we continue to include solutions for the rest of the Cat MineStar family. To keep up-to-date on the full MineStar Reporting roadmap, please visit Caterpillar’s website.

MineStar Reporting Benefits

MineStar Reporting can:

• consolidate data from disparate sources into a managed environment;
• remove duplication and inconsistencies;
• reduce the maintenance impact of legacy spreadsheets;
• remove the overhead of spreadsheet cut and paste;
• provide a globally designed database for consistent application of metrics and calculations;
• automate routine reporting;
• expose data to optimisation tools;
• measure business improvements easily;
• highlight constraints in process flows;
• conduct time-frame analysis;
• provide spatial and temporal data visualisations to any device; and
• shorten reaction time to exceptions.

Is Cat MineStar Reporting suitable for my operation?

Cat MineStar Reporting is a solution designed for any mining organisation already utilising one or more MineStar solutions (currently Fleet, Health, Command and Terrain).

How do I get MineStar Reporting?

To begin accessing all the benefits that come with MineStar Reporting you’ll need to get in touch with our Technology Team.