ToolFusion
πŸ“‹ Case Study

Iron Ore Mine ROC Consolidation in Western Australia

Fragmented legacy SCADA systems with inconsistent alarm protocols and manual handovers

πŸ—οΈ Project Overview

Rio Tinto’s Pilbara ROC consolidation across 8 open pit sites

🎯 Challenge

Fragmented legacy SCADA systems with inconsistent alarm protocols and manual handovers

πŸ”§ Design Approach

Unified IIoT platform with standardized OPC UA interfaces, centralized alarm management (ISA-18.2), and automated shift handover workflows

πŸ“ Design Diagram

Iron Ore Mine ROC Consolidation Western Australia β€’ IIoT Platform Integration Legacy SCADA (Fragmented) A B C β€’ Inconsistent alarm protocols β€’ Manual handovers (avg 22 min) Unified IIoT Platform OPC UA Standardized Interfaces ISA-18.2 Alarm Management ROC Output Alarm Flood ↓ 82% (Preβˆ’Post ROC) Handover Time ↓ 18 min (per shift)

AI-generated project design illustration

πŸ“ Key Calculations

Alarm Flood Reduction

(Pre-ROC Alarms/min) βˆ’ (Post-ROC Alarms/min)
Result: 82% reduction
Improved operator response time

Handover Time Savings

Avg Manual Handover Time βˆ’ Automated Handover Time
Result: 18 min/save
Reduced cognitive load and error risk

πŸ“Š Results

99.992% ROC uptime, 41% faster incident resolution, zero major handover omissions over 18 months

πŸ’‘ Lessons Learned

  • β€’Standardized data models are non-negotiable for scalability
  • β€’Operator co-design of alarm hierarchies increased adoption by 94%

βœ… Key Takeaways

  • 1Standardized data models are non-negotiable for scalability
  • 2Operator co-design of alarm hierarchies increased adoption by 94%