Mining has traditionally been cautious in its approach to technology adoption. Operational environments are complex, sites are often located in remote geographies, and any disruption to production can have significant cost implications. As a result, digital transformation in the sector has largely progressed in phases, with companies prioritising technologies that demonstrate clear operational and business value. However, this approach is now beginning to shift as mining operators increasingly look at connectivity-led digital systems to improve efficiency, safety and operational visibility across sites. In this context, private 4G and 5G networks are emerging as a critical enabler for connected mining operations. These networks are enabling a range of applications. As mining companies increasingly look to modernise operations, Gajraj Singh Rathore, Whole Time Director and Chief Operating Officer, JSW Steel Limited, discuss how connectivity-led digital transformation is reshaping their organisations, the key implementation challenges and their priorities for the future…
What are the most impactful digital or connectivity-driven use cases you are currently deploying or exploring? What measurable benefits have you seen so far?
We look at digital not as a technology layer, but as an operating lever. The most impactful use cases are those that improve field-level visibility, strengthen control and deliver measurable gains in productivity, reliability and cost efficiency. Our focus has been on applying connectivity and analytics where they directly improve mining execution, asset uptime and resource efficiency. That is where we are seeing clear business value.
In our mining operations, we have been running fully automated weighbridges, with end-to-end digital tracking from pithead to despatch using radio frequency identification, internet of things (IoT) devices and analytics dashboards that have delivered more than 15 per cent improvement in turnaround time across the loading-weighment-exit cycle and approximately 100 per cent elimination of manual register entries across despatch touchpoints.
Our fuel management system digitally monitors fuel issuance and consumption through flow meters, GPS/engine linkage and analytics. This gives us tighter control on fuel booking and consumption, while helping correlate fuel burnt with ideal hours, equipment availability, utilisation and cycle time to improve equipment productivity.
At the enterprise level, our asset intelligence layer with IoT sensorisation is already covering over 3,500 machines with predictive artificial intelligence (AI) models. This has helped us avoid more than 12,000 breakdowns, save thousands of production hours and achieve 99.98 per cent diagnostic accuracy.
What are the key use cases for private 4G/5G networks in metals and mining operations?
At JSW Steel, we see private 4G and 5G networks as a core enabler for connected, safer and more responsive operations in metals and mining. These networks are not only about connectivity, but they also create the digital backbone for real-time decision-making on the ground. Their value is highest where latency, mobility, visibility and control directly impact productivity and safety. That is where we are deploying and scaling use cases.
In mining, private networks enable real-time tracking of dumpers, loaders, drills and dozers through GPS and telemetry, along with live monitoring of fuel levels and equipment speed. This improves fleet visibility and operating control. They support real-time trip tracking from mines to siding locations, including the exact unloading point, which improves despatch visibility and movement control. Further, they facilitate digitally enabled fuelling operations on the ground. We have deployed a real-time monitoring application for diesel bowser operators that provides accurate information about fuel levels to prioritise refuelling of fleet and take decisions with full transparency.
A key emerging use case is fleet management systems over mine Wi‑Fi/private 5G, where real-time monitoring and mapping of shovel and dumper movement helps reduce idling hours and queuing time and improves mining efficiency. Private networks also enable real-time surveillance and AI-led safety use cases such as PPE detection, face recognition and geofenced attendance capture. These are important for workforce safety, compliance and control in large operating environments.
In our connected workforce programme, RAKSHAK, we strengthened shop floor safety across 25 departments, covering over 2,500 acres through deployment of more than 15,000 smart cards, supported by over 6,500 beacons and gateways, enabling real-time workforce visibility. The system is used to detect worker emergencies including trip and fall, lone worker tracking, hazard environment monitoring, etc., helping provide immediate assistance and supporting life-saving interventions. At a broader level, connectivity is enabling scale in condition-based monitoring and digital twins. Our condition-based monitoring programme has scaled to nearly 17,000 sensors and helped save thousands of production hours, while digital twins have supported real-time simulation, bottleneck prediction and throughput forecasting for better operational planning and stability.
With increased connectivity, how are you addressing cybersecurity risks in operational environments that were traditionally isolated?
Cybersecurity in connected operations is a core operational priority for us. As IT and OT environments converge, our focus is on securing connectivity without compromising safety, continuity, or production reliability.
We have strengthened a defence-in-depth architecture across both enterprise and operational environments. We maintain strict IT‑OT segregation with secure integration, controlled data flows, DMZs, firewalls, VLANs and micro-segmentation. We are embedding zero-trust and stronger access controls, including enhanced authentication, privileged access management and secure remote access. We have also upgraded data protection, continuous monitoring and threat detection to improve visibility and response speed. We are driving risk-based vulnerability, exposure and external attack surface management, with timely remediation. Furthermore, we have strengthened incident response, cyber resilience, third-party controls and workforce awareness to minimise operational disruption.
As metals and mining operations adopt private 4G/5G, IoT and cloud-driven remote operations, cybersecurity has evolved into a critical operational and safety imperative, requiring an integrated IT-OT security approach aligned with ISO 27001 standards.
What are the other key challenges that are slowing down digital transformation in the mining sector? What needs to change to accelerate adoption?
Device readiness is a major constraint. Many existing mining devices and field equipment are not 4G or 5G compatible, hence, additional rugged hardware and conversion equipment are needed for use in mining conditions. Older assets/equipment are harder to modernise. Legacy equipment comes with technology limitations and operational dependencies, which slow down adoption.
Moreover, private 5G is still expensive. The cost of network deployment, supporting infrastructure and compatible equipment is a practical barrier for scale-up. Cybersecurity becomes more critical with advanced connectivity. Higher connectivity increases exposure to cyber risks, hence, network architecture, vendor selection and security design have to be right from the beginning. This can impact project timelines.
Protocol and vendor compatibility are another issue. Many original equipment manufacturers follow their own communication protocols; so, additional devices, converters and integration efforts are needed to make systems work on advanced networks.
This adds both cost and complexity. Business ownership and cross-functional alignment are equally important and unless operations, maintenance, despatch, safety and IT move with one mindset, digital adoption remains fragmented.
To overcome these challenges, we need phased modernisation of legacy equipment with clear prioritisation. We need stronger interoperability and integration standards across devices and vendors. In addition, a need to balance cost, scalability and cybersecurity from the design stage itself is required.
How do you expect advanced connectivity technologies to reshape mining operations over the next three to five years in terms of efficiency, sustainability and safety?
Advanced connectivity will enable real-time visibility, faster decisions, safer operations and more connected execution across the mine. In mining, where mobility, latency and field responsiveness matter, advanced connectivity through private 4G/5G, edge-connected devices, smart sensors and integrated field networks will increasingly become a core operational utility.
Advanced connectivity will enable real-time tracking of fleet movement, equipment status, trip execution and material flow across the mine. This will improve despatch control, reduce idling and queuing, improve asset utilisation and support faster operational decisions. It will also enable more synchronised mine operations, where decisions are taken on live field data rather than delayed reporting.
Advanced connectivity will power collision detection, proximity warning, connected surveillance, geofencing and real-time workforce monitoring. This will shift safety from reactive response to predictive and preventive intervention. It will also support wearables, gas sensors, fatigue monitoring and live field alerts, giving supervisors real-time visibility of workforce exposure and risk across the mine.
AI-enabled surveillance systems running on advanced connectivity will help identify unsafe behaviour, PPE non-compliance, fatigue indicators and restricted-area intrusion in real time. Moreover, it will be the base for more automated and autonomous mining operations, where systems can guide movement, monitor conditions continuously and support faster, more reliable execution on the ground.
