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Contact UsHow Appinventiv unified disconnected operational and corporate technology across nine remote mining sites into governed, real-time operational intelligence, without disrupting live production.
Nine sites had grown their own systems in isolation, leaving the enterprise with no shared view of equipment health, emissions data, or safety status across the operation.
SCADA systems, PLCs, and equipment telemetry had no structured pathway into the corporate cloud. The OT and IT boundary was strictly air-gapped for safety, leaving real-time operational data invisible to executive decision-makers.
With no consolidated asset health data, teams had no early warning. Unplanned breakdowns triggered expensive emergency mobilisations, including helicopter dispatch and multi-day production stoppages, that earlier visibility could have prevented.
Site managers submitted emissions data through disparate spreadsheets, consolidated only at period end with no data lineage. NGER non-compliance had become a board-level concern.
Several sites ran on intermittent satellite links. Any architecture had to process and act on data locally, then synchronise once connectivity returned. Cloud-dependent systems simply failed.
Gas detection, wearables, and personnel tracking each fed separate dashboards, with no central workflow to confirm whether an alert from an underground section had been acknowledged and actioned.
Appinventiv connected OT and IT behind a secure boundary, processed data at the edge for remote resilience, and automated NGER reporting, all without disrupting live production.
Industrial IoT gateways at each site capture telemetry from heavy equipment and SCADA outputs, normalising it into a structured schema before forwarding to the cloud. The OT and IT boundary follows IEC 62443 principles: no direct path from control systems to cloud, with all data transiting a secure DMZ that uses protocol breaks and deep packet inspection.
Edge computing nodes process safety monitoring and vital telemetry locally at each site. If a satellite link drops, the site keeps running, caching data and synchronising automatically the moment connectivity is restored.
Fuel, electricity, and fleet runtime data ingest automatically from source assets across all nine sites. A custom module maps live data to NGER carbon accounting categories, generating audit-ready disclosures with full provenance and moving sustainability teams from lagging reports to proactive carbon management.
Discovery and architecture design at priority sites, edge deployment tested in isolation before going live, predictive and ESG intelligence activation, then enterprise-wide rollout with role-based access and an activated audit and data governance framework.
Aligned to the ASD Essential Eight and the SOCI Act. All audit logs, environmental data, and asset telemetry are stored exclusively in Australian cloud regions, with role-based controls and tamper-proof, immutable data lineage for every NGER metric.
Telemetry, asset health, emissions, and safety alerts now flow into one governed view, cutting downtime and reporting cycles while keeping every site running through satellite outages.
Nine sites running in isolation became one governed operation. Here is what changed across OT integration, maintenance, and ESG reporting once the platform went live.
OT/IT integration: Fully siloed; no data flow
between
equipment
and enterprise systems.
Maintenance: Reactive; failures triggered
costly remote
mobilisations.
ESG reporting: Manual spreadsheets, six-
week reconciliation,
no
lineage.
OT/IT integration: Secure, real-time telemetry on a
governed
architecture, raw equipment to executive view.
Maintenance: Condition-based; predictive models auto-
generate
prioritised work orders.
ESG reporting: Automated pipeline; audit-
ready NGER
disclosures in
under two weeks.
Predictive maintenance also cut technician mobilisation costs by 27%. Operational data now flows from raw equipment to the executive view in real time, and NGER disclosures are audit-ready by default across all nine sites.
Modernising legacy mining infrastructure?
Talk to us about OT and IT convergence, predictive asset management, and audit-ready ESG reporting for multi-site Australian operations, without disrupting live production.
Most multi-site engagements run between 6 and 18 months from discovery through to enterprise-wide rollout. That accounts for OT network assessment, safety boundary validation, edge hardware deployment, data pipeline engineering, and phased site activation. A single-site pilot can typically be completed in four to six months.
Control systems are treated as integration sources throughout; never migration targets. The existing OT infrastructure stays in place and in operation. Integration works through read-only telemetry extraction at the edge, with zero direct write-back connectivity to safety-critical systems.
Yes. Edge computing nodes at each site process and store data locally, keeping safety monitoring and equipment telemetry active regardless of satellite status. Data synchronises to the central platform automatically when connectivity is restored, ensuring zero data loss during WAN blackouts.
