Innovation at Its Core: Hudbay’s Strategic Bet on Jebi’s GET Smart

Executive Summary

Jebi Technologies and Hudbay Minerals have forged a groundbreaking partnership through the implementation of the GET smart system, revolutionizing Ground Engaging Tool (GET) management in mining operations. This collaboration addressed key challenges such as GET detachment detection, especially for vertical shrouds, and operational efficiency in harsh mining conditions without internet connectivity. The project has delivered significant improvements in operational efficiency, safety, and cost savings, alongside enhancing data analytics and reporting capabilities. The successful deployment at Hudbay Minerals showcases the potential of Jebi Technologies’ innovations to set new industry standards, prompting a promising future for further technological advancements and collaborations in mining safety and operational efficiency.

Introduction

Jebi Technologies, a pioneering force in the realm of artificial intelligence and machine learning, specializes in crafting cutting-edge solutions tailored for the mining industry. Founded with the vision to enhance operational efficiency, safety, and sustainability, Jebi has been at the forefront of integrating smart technologies into the challenging environments of mining operations.

Hudbay Minerals, a notable player in the mining sector, is renowned for its commitment to innovation and excellence. Operating across North and South America, Hudbay focuses on the discovery, production, and marketing of base and precious metals. In its quest to elevate operational standards and ensure the utmost safety, Hudbay sought a transformative solution to a persistent challenge in the mining industry: the effective management of Ground Engaging Tools (GETs).

The GET smart project, initiated in 2020, stands as a collaboration between Jebi Technologies and Hudbay Minerals, aimed at revolutionizing GET management through Jebi’s proprietary technology. This partnership was driven by a mutual commitment to leveraging technological advancements for operational improvements.

Ground Engaging Tools are critical components of mining equipment, subject to intense wear and tear. Effective management of these tools is paramount to maintaining operational efficiency and preventing costly downtime. Prior to the adoption of Jebi’s GET smart system, Hudbay faced challenges in tracking, monitoring, and managing GETs, impacting both safety and productivity.

The GET smart system, developed by Jebi Technologies, introduces an AI-driven approach to monitor and manage GETs in real-time. This innovative system not only enhances the safety and efficiency of mining operations but also provides actionable insights, leading to improved decision-making and reduced operational costs.

The inception of the GET smart project at Hudbay marks a significant milestone in the mining industry, showcasing the potential of AI and machine learning to tackle complex challenges and drive forward operational excellence.

Overview of the GET smart project’s objectives

The GET smart project, spearheaded by Jebi Technologies in partnership with Hudbay Minerals, was strategically initiated to address critical challenges faced in the management and operation of Ground Engaging Tools (GETs) within Hudbay’s mining activities. The project was rooted in a set of precisely defined objectives aimed at solving specific operational problems, enhancing safety, and ensuring the efficiency of mining operations under Hudbay’s unique conditions:

  • Preventing Crusher Blockages: The primary objective was to address the significant issue of GETs, particularly vertical shrouds, becoming lodged in the main crusher—a scenario that leads to considerable operational downtime, financial losses, and poses substantial risks during the processes of freeing and repairing the crusher.
  • Detection of Vertical Shrouds: Hudbay required a bespoke solution capable of detecting the detachment of vertical shrouds, the GETs most prone to falling off in their operations. This specific need highlighted a gap in the market, as no available solution could effectively monitor these particular GETs.
  • Offline Operation: Given the limited connectivity in the mine pit where the excavators operated, the solution needed to function entirely offline, without access to the internet. This requirement was critical for ensuring continuous, reliable monitoring and detection capabilities in the challenging mining environment.
  • Local Support: Recognizing the inadequacies of support from foreign companies offering GET management solutions, Hudbay emphasized the need for reliable local support. This consideration was vital to ensure timely and effective assistance, maintenance, and troubleshooting directly from the solution provider.

By focusing on these objectives, the GET smart project aimed to deliver a cutting-edge, reliable solution tailored to Hudbay’s specific operational needs and challenges. Jebi Technologies’ commitment to innovation, coupled with a deep understanding of Hudbay’s requirements, set the foundation for a project poised to redefine GET management in the mining industry, prioritizing safety, operational continuity, and cost-efficiency.

Challenge

Before the implementation of Jebi’s GET smart system, Hudbay faced several significant challenges in the management of Ground Engaging Tools (GETs), which impacted operational safety, efficiency, and incurred high costs. Addressing these challenges required a blend of innovation, technological sophistication, and an understanding of the rugged mining environment.

  1. Unpredictable GET Detachments:

The most pressing challenge was the unpredictability of GET detachments, including the critical but hard-to-monitor vertical shrouds. These components could become detached during regular operations, posing serious risks. The difficulty was compounded by the vertical shrouds’ position, which made them nearly invisible from the conventional fixed camera positions on the front shovel, hindering timely detection and response.

  1. Harsh Operational Conditions:

Mining excavators operate under extreme conditions, facing dust, mud, heavy vibrations, and fluctuating temperatures day and night. Protecting the delicate, state-of-the-art monitoring systems from such harsh conditions was a considerable challenge, necessitating robust and resilient design solutions that could withstand the mining environment’s rigors.

  1. Operator Interface Design:

The operator’s cabin was already cluttered with numerous screens and instruments, adding to the complexity of integrating a new system. Designing an operator interface that provided critical GET detachment alerts without distracting the operator required careful consideration to enhance safety without adding to the operator’s cognitive load.

  1. Need for an Autonomous Local Solution:

Given the lack of reliable connectivity within the mining pit, another significant challenge was developing a fully autonomous local solution. The system needed to operate independently of network or internet access, ensuring continuous and reliable monitoring and detection capabilities without external dependencies.

Impact on Safety, Efficiency, and Costs:

The inability to promptly detect and respond to GET detachments posed severe safety risks, potentially leading to equipment damage, operational disruptions, and hazardous conditions for the workforce. These challenges directly impacted operational efficiency, as undetected GET losses could result in unplanned downtime, extensive damage to the crusher, and costly repairs. Furthermore, the operational inefficiencies and increased risk of equipment failure led to significant financial losses, stemming from repair costs, downtime, and reduced productivity. Addressing these multifaceted challenges was critical for enhancing safety, optimizing operational efficiency, and minimizing costs, paving the way for the development and implementation of the GET smart system.

Solution

To overcome the challenges Hudbay faced with GET management, Jebi Technologies introduced the GET smart system, a comprehensive solution designed to monitor, detect, and alert the detachment of Ground Engaging Tools (GETs) in real-time. This solution was specifically tailored to meet Hudbay’s operational needs, ensuring enhanced safety, efficiency, and cost-effectiveness in their mining operations.

Description of the GET Smart System and Its Components:

The GET smart system is an advanced monitoring solution that employs artificial intelligence and machine learning to detect the detachment of GETs, including the hard-to-monitor vertical shrouds. The system comprises several key components:

  • Sensors and Cameras: Deployed strategically around the excavator to capture real-time data on GETs’ status. These are designed to withstand the harsh mining environment and provide comprehensive coverage of all GETs.
  • Edge Processing Unit: A rugged, autonomous computing device that processes data locally, ensuring the system operates effectively even without internet connectivity. This unit analyzes the data from sensors and cameras, identifying any GET detachments immediately.
  • Operator Interface: A user-friendly interface integrated into the existing cabin setup, designed to alert operators without causing distractions. It uses clear visual and auditory signals to notify operators of any GET detachments, ensuring quick response times.
  • Data Analytics Platform: While the system operates offline, it also features a data analytics platform for detailed analysis and reporting whenever connectivity is available. This allows for deeper insights into GET performance and wear patterns.

Rationale Behind Choosing Jebi’s GET Smart Solution for Hudbay:

Jebi’s GET smart system was selected for its ability to provide a comprehensive, real-time monitoring solution that specifically addressed Hudbay’s challenges. Its capacity to detect all types of GETs, including vertical shrouds, in a wide range of operational conditions set it apart from other solutions. The system’s robust design, capable of withstanding the extreme conditions of the mining environment, and its autonomous operation were crucial factors in its selection. Moreover, Jebi’s commitment to providing local support ensured Hudbay would receive timely assistance and maintenance services, further solidifying their decision.

Implementation Process:

The implementation of the GET smart system at Hudbay followed a structured process, encompassing planning, installation, and training phases:

  • Planning: This phase involved detailed site assessments to determine optimal sensor and camera placements, ensuring comprehensive coverage of all GETs. Collaboration between Jebi and Hudbay’s teams was crucial to tailor the system to Hudbay’s specific operational needs.
  • Installation: Jebi’s technical team undertook the installation, meticulously mounting sensors, cameras, and the edge processing unit on the excavators. The process was carefully planned to minimize downtime and ensure seamless integration with existing equipment.
  • Training: Comprehensive training sessions were provided to Hudbay’s operators and maintenance staff, focusing on system functionality, interface navigation, and response protocols for GET detachment alerts. Ongoing support and refresher training ensure the system’s effective use and maximization of its benefits.

The successful implementation of Jebi’s GET smart system at Hudbay signifies a landmark achievement in GET management, showcasing the potential of technology to enhance mining operations’ safety and efficiency.

Results

Quantitative Results:

GET Management Efficiency: The introduction of the GET smart system has substantially increased the efficiency of GET management. The real-time monitoring and instant alert system have reduced the frequency of manual inspections, leading to a notable decrease in equipment downtime. 

  • Safety Improvements: By providing immediate alerts on GET detachments, the system has significantly minimized the risk of accidents and equipment damage. The rate of incidents related to GET failures has seen a dramatic decrease, enhancing overall workplace safety for Hudbay’s operations.

  • Cost Savings: The GET smart system’s impact on reducing unplanned downtime and preventing equipment damage has led to considerable cost savings. 

Qualitative Feedback:

Operators have praised the GET smart system for its intuitive interface and non-intrusive alerts, which have made it easier for them to stay informed about GET status without being overwhelmed by additional screen information.

Management has highlighted the system’s contribution to improving operational decision-making and planning, thanks to the actionable insights provided by the data analytics platform.

Both operators and management have appreciated the local support from Jebi Technologies, emphasizing the swift response and effective solutions to any issues encountered.

Comparative Analysis of Performance Metrics Before and After GET Smart Implementation:

Before Implementation: Frequent GET-related stoppages and manual checks were common, with significant downtime impacting productivity. The lack of real-time monitoring led to delayed responses to GET detachments, increasing safety risks and operational costs.

After Implementation: The GET smart system has transformed GET management at Hudbay, with real-time data allowing for prompt action and substantially reducing downtime. The system’s effectiveness is evident in the improved performance metrics, showcasing enhanced efficiency, safety, and cost-effectiveness in Hudbay’s mining operations.

Benefits

The implementation of Jebi’s GET smart system at Hudbay Minerals has led to a range of significant benefits, directly addressing the initial challenges and objectives set forth at the project’s inception. These benefits have not only enhanced operational efficiency and safety but also provided financial advantages and improved analytical capabilities.

Increased Operational Efficiency:

Streamlined GET Management: The automation of GET monitoring has significantly streamlined the management process, allowing for more precise and efficient scheduling of maintenance activities. This has reduced the burden on operational staff and increased the time available for productive work.

Enhanced Equipment Utilization: Real-time monitoring and alerts have minimized the duration and frequency of equipment stoppages for manual GET checks, thereby increasing equipment availability and utilization rates across Hudbay’s operations.

Enhanced Safety Measures:

Proactive Risk Mitigation: The immediate detection of GET detachments has dramatically reduced the risk of accidents associated with GETs entering the crushing circuit or causing damage to other machinery. This proactive approach to safety has contributed to a safer working environment for all personnel.

Improved Workplace Safety: The overall enhancement of workplace safety protocols, through the integration of the GET smart system, has fostered a culture of safety and awareness among the workforce.

Reduced Downtime and Maintenance Costs:

Minimized Unplanned Downtime: By avoiding critical equipment failures and blockages in the crusher, the GET smart system has substantially reduced unplanned downtime, leading to more consistent operational performance and output.

Lower Maintenance Expenses: The early detection of GET issues allows for timely intervention, preventing minor problems from escalating into major failures. This has resulted in lower maintenance and repair costs, contributing to overall cost savings.

Improved Data Analytics and Reporting Capabilities:

Actionable Insights: The system’s data analytics platform provides Hudbay with actionable insights into GET wear patterns and performance. This enables more informed decision-making regarding GET management and maintenance strategies.

Enhanced Reporting: Improved data collection and analysis capabilities have enhanced reporting on GET performance and operational efficiency. These reports support continuous improvement initiatives and provide valuable feedback for both operational planning and strategic decision-making.

Testimonials

The implementation of Jebi’s GET smart system at Hudbay has not only revolutionized GET management but also fostered a strong partnership between Jebi Technologies and Hudbay Minerals. Here are potential testimonials from key Hudbay personnel reflecting on their experience with the GET smart system and collaboration with Jebi.

Christian Alarcon, Head of Mine Maintenance Planning and Reliability, Hudbay Minerals:

“Working with Jebi Technologies to integrate the GET smart system into our operations has been a transformative experience. The system’s precision and reliability in monitoring GETs have significantly improved our maintenance planning and operational reliability. It’s rare to find a solution that so effectively addresses a longstanding industry challenge, but GET smart has done exactly that. Jebi’s commitment to innovation and their hands-on approach to support have made them invaluable partners in our continuous improvement journey.”

Placeholder for Visual: Photo of Christian Alarcon with GET smart system in the background.

Adrian Conza, Head of Mine Maintenance, Hudbay Minerals:

“The introduction of the GET smart system from Jebi Technologies has marked a significant milestone in our quest for operational excellence. The system’s impact on our efficiency and safety is undeniable. Not only has it reduced downtime and maintenance costs, but it has also enhanced the safety of our workforce by proactively preventing potential GET-related incidents. Jebi’s local support team has been instrumental in the smooth implementation and ongoing success of this project, demonstrating an exceptional level of service and technical expertise.”

Placeholder for Visual: Graph showcasing reduction in downtime and maintenance costs before and after GET smart implementation.

Future Outlook

The successful implementation of Jebi’s GET smart system at Hudbay Minerals has set the stage for a promising future, with both entities looking forward to deepening their partnership through further technological enhancements and exploring new areas of collaboration. The roadmap ahead is marked by continuous innovation aimed at augmenting the value delivered to Hudbay through Jebi’s pioneering technology.

Planned Upgrades and Expansions of the GET Smart System at Hudbay:

Enhanced Detection Capabilities: Ongoing development efforts are focused on further refining the GET smart system’s detection capabilities, including improved accuracy in monitoring and alerting for GET detachments. This will ensure even more reliable protection against operational interruptions and equipment damage.

Integration of Predictive Analytics: Future upgrades include the integration of predictive analytics into the GET smart system. This will enable Hudbay to anticipate GET wear and maintenance needs more accurately, optimizing maintenance schedules and extending the lifespan of GETs through data-driven decision-making.

Expansion to Additional Equipment Types: The scope of the GET smart system is set to expand, covering a wider range of mining equipment and machinery. This broadened application will enhance operational efficiency and safety across more aspects of Hudbay’s mining operations.

Potential New Areas of Collaboration Between Jebi and Hudbay:

Mine Safety Initiatives: Jebi and Hudbay are exploring new technologies focused on enhancing mine safety. This includes the development of systems for monitoring and managing environmental hazards and ensuring worker safety in and around the mine.

Operational Efficiency Projects: Both parties are keen on identifying opportunities to leverage Jebi’s technology in areas beyond GET management. This includes optimizing logistics, material handling, and equipment utilization to improve overall operational efficiency.

Custom Technology Solutions: Recognizing the unique challenges and opportunities within Hudbay’s operations, Jebi is committed to developing custom technology solutions tailored to meet specific needs. This collaborative approach ensures that innovations are directly aligned with Hudbay’s strategic objectives and operational requirements.

The partnership between Jebi Technologies and Hudbay Minerals is poised for growth, driven by a shared commitment to leveraging technology for operational excellence and safety. The future outlook is bright, with both entities dedicated to exploring new technological frontiers and continuing to set industry benchmarks for innovation and efficiency in mining.

Conclusion

The GET smart project between Jebi Technologies and Hudbay Minerals marks a significant leap in mining operations, showcasing how innovative technology can enhance safety, efficiency, and cost-effectiveness. This partnership not only solved critical operational challenges but also set new benchmarks in GET management through real-time monitoring and AI-driven analytics. The success story serves as a compelling case for the mining industry, demonstrating the transformative potential of integrating advanced technologies into traditional mining practices.

Call to Action

We encourage mining companies seeking to overcome similar challenges and improve their operational efficiencies to reach out to Jebi Technologies. Discover how our GET smart system or other innovative solutions can be customized to meet your specific needs. For more information or to schedule a demonstration, please visit our website at [Jebi’s website] or contact us directly at [contact information]. Let Jebi Technologies help you navigate the future of mining with cutting-edge solutions designed for success.

 

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