WCL — multi-block HEMM coordination across open-cast coal operations.

Coordinating dozens of HEMM across multiple blocks via phone calls.

WCL operates open-cast coal blocks across central India with different shift timings, contractor mixes, and production targets in each. The day-to-day coordination of which shovels go to which faces, which dumpers haul to which dump points, which dozers prepare which areas — was managed through spreadsheets updated at shift handover and phone calls between shift in-charges throughout the day.

The cost of this coordination model was invisible but compounding: idle equipment waiting for assignment clarity, fuel consumption higher than necessary because cycle inefficiencies weren't visible until end-of-shift reports, and safety incidents occurring in coordination gaps where attention had moved away from a particular block or face.

• Multi-block coordination via spreadsheets and phone calls — high latency, error-prone
• Equipment idle time not visible until end-of-shift summary — already a sunk cost
• Fuel consumption variance between blocks unexplainable from available data
• Production targets vs actual visible only at shift-end — no in-shift correction window
• Contractor performance not comparable across blocks — different recording methods

One dashboard. Every HEMM. Every block. Live.

Cognecto deployed Boson IoT connectivity across WCL's existing HEMM fleet — TATA, BEML, and mixed OEM telematics all normalised into one schema. The mine operations dashboard shows live equipment status, production against target, fuel consumption per asset, and maintenance schedule for every machine across every block in one interface. Shift in-charges see their block. The general manager sees them all.

In-shift visibility replaced end-of-shift reconstruction.

WCL operations are now managed in real time — not reconstructed from after-the-fact reports. Decisions to redeploy equipment, change shift targets, or address bottlenecks happen during the shift, not after it. Production gains, fuel savings, and incident reduction all follow directly from this shift in operational visibility.