The Road That Came With Proof
Shift Planning · Fleet · Fuel · Maintenance · Safety · Blasting
Every shift planned.
Every tonne accounted for.
Cognecto unites every HEMM asset, operator, and workflow into one real-time layer. From pre-start checklists to end-of-shift reports—gain absolute visibility with zero manual entries.
Module 01
Shift Planning
Operator assignment, crew readiness, digital handover
Module 02
Production & Haul Cycles
Ore, OB, reclaim — automated trip recording
Module 03
Fuel Management
Issue vs consumed reconciliation, pilferage detection
Module 04
Maintenance & Inventory
Predictive alerts, job cards, SAP integration
Module 05
Haul Road Monitoring
Route optimisation, overloading, road condition
Module 06
Operator Attendance
Skill-based assignment, biometric, overtime tracking
Module 07
Plant Monitoring
Crusher, conveyor, plant load dispatch
Module 08
Digital Blasting
Drill logs, charge sheets, blast zone safety
Mining output · North Eastern Mining Australia
2×
"Achieved 2x equipment uptime and complete traceability with Cognecto's smart maintenance platform."
Mines across India, Australia & Africa
20+
Deployments generating live operational data—haul cycles, fuel rates, and HEMM utilisation.
Trip reporting accuracy · AI vs manual
99%
Automated trip logs capture ore, overburden, and reclaim cycles with zero operator input.
Module 01Shift Planning & Operator Management
The right operator.
The right machine.
Every shift.
Manual shift prep burns 30–50 minutes just matching operators, verifying attendance, and setting targets.
Cognecto cuts this to under 5 minutes. Pre-loaded certification data auto-matches operators to HEMM classes. Your dashboard centralizes crew availability, asset readiness, and targets, while digital handovers eliminate lost information between shifts.
Skill-based assignment — certified operators matched to HEMM class automatically
Crew availability dashboard — attendance, overtime, and manpower readiness live
Digital handover notes — seamless communication across shift boundaries
Equipment readiness checks — pre-start status confirmed before deployment
Task allocation — shift targets set and tracked against live completion %
50%
Reduced shift preparation time per shift
<5 min
Pre-start time per asset with digital checklist
5–10%
Higher shift output vs manual planning baseline
<5%
Unplanned downtime during planned shifts
Module 02Production Reporting & Haul Cycle Analytics
Every tonne tracked.
Every cycle analysed.
End-of-shift tally sheets mean that by the time you spot a bottleneck or an idle shovel, the efficiency window has closed.
Cognecto's IoT auto-captures every load-haul-dump cycle, classifying ore, OB, and reclaim in real time. The live dashboard exposes shift targets, shovel productivity, and queue delays before they erode your output.
Auto-detected haul cycles — loading, hauling, dumping, return stages all captured
Ore / OB / reclaim classification — automatic, by specification, no manual entries
Shovel productivity insights — operators, material types, shift performance compared
Cycle time analytics — average and outlier times per phase, bottleneck flagging
Contractor performance matrix — productivity, turnaround, and fuel efficiency ranked
Daily Production Report · Jan 31 – Feb 4, 2024 · Ore + Plant Load + Reclaim
DateMining TripsPlant Load (t)Reclaim (t)Trend
04 Feb 202445115,7851,240↑ On target · 01:11 elapsed
03 Feb 202441314,5551,180↑ On target · 05:12 elapsed
02 Feb 20241123,920340âš Underperforming · Weather delay flagged · 06:22
01 Feb 202445315,8551,260↑ On target · 09:22 elapsed
31 Jan 202440814,2801,155↑ On target · 03:45 elapsed
All production data auto-generated from IoT trip recording. Zero manual entries. Exportable to SAP and SCCL/CIL reporting formats.
9–10%
Increase in daily output vs manual planning baseline
10–12%
Faster cycle times from bottleneck identification
40%
Increased operational transparency vs paper-based logs
90%
Reduction in manual data entry and reporting effort
Platform modulesEight modules.
Request a demo →
Eight modules.
One connected mine.
Module 03 · Fleet
Fuel Management & Pilferage Detection
Track fuel from purchase to consumption per asset. Analytics spot refill discrepancies and pilferage instantly, auto-reconciling issued vs. consumed fuel for up to 7% loss reduction.
Module 04 · Asset
Predictive Maintenance & Inventory Control
Sensor-based fault detection on engines/hydraulics provides 7–15 days notice before breakdown. Features digital job cards, stock alerts, and SAP integration to boost uptime by 12%.
Module 05 · Haul Road
Haul Road Monitoring & Route Optimisation
Track tippers in real time. Overloading alerts and route optimization eliminate queue congestion. Vision AI flags road deterioration to prevent accidents and equipment damage.
Module 06 · Workforce
Operator Attendance & Skill Management
Biometric attendance ends buddy punching. Digital skill tracking feeds the shift planner to ensure only certified operators run HEMMs. Automates DGMS compliance and overtime tracking.
Module 07 · Plant
Plant Monitoring & Load Dispatch
Track crusher throughput and conveyor status against daily targets. Live data shows which bench is feeding the plant, while auto-updating dispatch schedules based on actual haul cycles.
Module 08 · Blasting
Digital Blasting Workflow & Explosive Inventory
Digitize explosive inventory. Log charge usage, hole counts, and powder factors per blast. Auto-track bedrock volume and muckpile tonnage for tight cost control and compliance.
AI Co-pilot · Mining Intelligence
Real-time control centre.
Real-time control centre.
One screen for the entire mine.
Consolidate HEMM positions, production KPIs, and safety alerts into a single command interface for total situational awareness.
The AI co-pilot goes further, driving automated statistical summaries (mean cycle times, variance) and allowing natural language queries. Ask, "Which excavator is underperforming?" or "Where is the longest queue?" and get instant answers without manual data crunching.
Exception-based alarms — idle fleet, over-speeding, unauthorised routes, stoppages
Interactive mine map — live position of all HEMM, benches, and dump points
Plan vs actual production — shift targets vs real-time progress, live
Driver Monitoring System — fatigue and distraction detection via AI vision
ANPR access control — license plate recognition for equipment entry/exit logging
OEE dashboards — availability, performance, and quality across the fleet
In the field. On the record.
Deployed across coal, lignite,
Deployed across coal, lignite,
bauxite, and gemstone operations.
9–10%
Output increase
7%
Fuel loss reduction
20%
Fewer incidents
"Managing HEMM fleets across multiple open-cast blocks with different shift timings, contractor mixes, and production targets was a coordination challenge we solved through spreadsheets and phone calls. Cognecto gave us one dashboard where every shovel, dumper, and dozer is visible in real time — with production against target, fuel consumed, and maintenance due. We stopped finding out about problems at the end of shift."
9–10%
Daily output increase
7%
Fuel pilferage reduction
20%
Fewer operational incidents
Western Coalfields Limited · Open-Cast Operations · Nagpur, India
NLC India · Naveli Lignite Corporation · Tamil Nadu
Hindalco · Aluminium & Copper Mining Operations · India
FG Gold · Gold Mining Operations · West Africa
Why CognectoWhy mining operators
Why mining operators
choose Cognecto over everything else.
Not a generic fleet tracker. Not a dashboard with manual inputs. An end-to-end mining intelligence platform built on real operational data from 20+ mines across coal, bauxite, lignite, gold, and gemstone operations.
01 / Multi-OEM From Day One
Every device. Every manufacturer. One schema.
Boson's codec library normalises proprietary formats (TATA, BEML, Komatsu) into one schema. Bring your existing fleet; we connect without hardware replacement or complex integration projects.
02 / IoT + Vision AI Together
Telematics and cameras from the same data model.
Boson tracks telematics (cycles, fuel, health), while Photon monitors visual data (PPE, proximity, roads). Both feed the Cortex knowledge graph to deliver unified shift reports without data silos.
03 / Built for Indian Mining Compliance
DGMS, CIL, SCCL — native compliance reporting.
Built-in DGMS pre-start checklists and statutory blast records. Native CIL/SCCL MIS exports and contractor performance matrices mean compliance is hardwired into your daily workflow.
04 / Predictive, Not Reactive
7–15 days advance notice on every maintenance event.
Achieve 2× uptime and slash emergency procurement by receiving maintenance alerts before failure. Service is driven by actual hour readings, preventing breakdowns instead of just logging them.
Common questions
Everything you need to
Everything you need to
evaluate for your mine.
Questions specific to coal, lignite, bauxite, or hard rock operations? Our team responds within 2 hours.
Request a demoDoes Cognecto work with BEML, TATA, and other Indian HEMM manufacturers?
Yes. Boson ships with codecs for 20+ OEM telematics manufacturers including BEML, TATA Advance, 808GPS, Mahindra, Fleetedge, and custom TCP/MQTT devices used in many Indian mines. If your equipment isn't in the library, we build the codec in 5 business days. You bring your existing fleet — we connect to it. No hardware replacement required.
How does automated trip recording work without driver input?
Boson's GPS and sensor data detects loading events (weight sensor spike or shovel proximity), haul movement, dumping events (load drop), and return cycle automatically. The AI classifies each trip as ore, overburden, or reclaim based on the source bench and destination dump point configuration. Operators do not need to log anything — the system records every cycle accurately without human intervention, eliminating the discrepancies that come from manual trip sheets.
How does fuel reconciliation and pilferage detection work?
Fuel sensors on each HEMM record real-time fuel levels. When a refill event occurs, the system records volume dispensed against the dispenser flow meter. GPS-calculated expected consumption (based on haul distance and load) is compared against actual consumption per shift. Discrepancies above a configurable threshold trigger a pilferage alert with the asset, location, and time. The digital workflow connects to your ERP — fuel purchased, issued, consumed, and lost are all reconciled in one report.
Can the platform handle contractor vs departmental workforce separately?
Yes. Contractors and departmental operators are managed as separate workforce pools within Cognecto. Each pool has its own skill registry, certification tracking, and attendance records. Production reports, fuel consumption, and cycle time analytics can be filtered and compared by workforce type — giving you the contractor performance matrix needed for renewal decisions and penalty clauses. Overtime tracking runs separately for each category.
Does Cognecto integrate with SAP for maintenance and inventory?
Yes. The maintenance module is SAP-compatible — service reminders are pushed to SAP PM (Plant Maintenance) and inventory low-stock alerts sync with SAP MM (Materials Management). Job cards created in Cognecto can be exported in SAP-compatible formats. Organisations without SAP can use Cognecto's native inventory and job card system independently. The integration is bidirectional — SAP can also trigger Cognecto maintenance workflows.
What does deployment look like for a mine with 50+ HEMM units?
Typical deployment for a 50+ HEMM mine runs 2–3 weeks: device onboarding and codec configuration (Week 1), shift planning and production module configuration with your BOQ and targets (Week 2), safety and maintenance module setup with pre-start checklists and service schedules (Week 3). Dashboard access is provisioned role-by-role — shift in-charge, plant manager, safety officer, and mine manager — each with the right data and the right permissions from day one.
8 modules. One platform. Active in 7 days.
Your mine is already
Your mine is already
generating the data.
Cognecto makes it work.
Connect your existing HEMM fleet and site cameras. Configure shift schedules, production targets, and BOQ. Go live across all eight modules within a week. No hardware purchase. No IT overhead. Every tonne tracked from the first shift.
✓ 20+ HEMM OEM integrations live
✓ DGMS-compliant pre-start checklists
✓ Active across WCL · NLC · Hindalco · FG Gold
✓ SAP-compatible maintenance & inventory
Frequently Asked Questions
Find answers to common questions about our platform and deployments.
Cognecto provides an end-to-end AI and IoT platform for open-cast mines, covering shift planning, haul cycle analytics, fuel management, predictive maintenance, operator attendance, blasting workflows, and a real-time control centre. It is active across WCL, NLC, Hindalco, and FG Gold mining operations.
Cognecto uses GPS telemetry and vision AI to track every dump truck, excavator, and loader in real time. The platform optimizes haul routes, reduces idle time, monitors fuel consumption per trip, and provides shift-wise productivity reports for mine managers.
Cognecto deploys Boson Listener sensors on heavy mining equipment to capture vibration data, GPS coordinates, engine telemetry, and fuel consumption. Photon Vision cameras monitor safety zones, material loading quality, and operator compliance.
Cognecto's Photon Vision AI cameras detect PPE violations, unauthorized zone entry, proximity hazards near heavy equipment, and unsafe operator behavior in real time. Alerts are sent to the safety control room within seconds.
Cognecto is deployed at Western Coalfields Limited (WCL), NLC India Limited, Hindalco Industries, FG Gold Mining, Fura Gems, Canyon Resources, and CAMALCO across India, Australia, Cameroon, and Colombia.