It’s 2 A.M. at a remote mining site. The control room operator’s screen has become a Christmas tree, multiple sensors are flashing red, signalling a sudden spike in pressure along the slurry transfer pipeline. Alarms are blaring, but the night shift team hesitates: Should they shut the plant down, call maintenance, or wait for a supervisor? Minutes tick by, production targets falter, safety risks escalate, and a potential environmental incident is incoming.
For operations teams in mining, metals, and minerals (MMM), this kind of scenario isn’t just stressful: It can be costly. Unplanned downtime can drain upwards of $125,000 per hour, according to ABB’s survey.
Now, imagine a different outcome: A system instantly flags an abnormal deviation, guides the team through pre-approved corrective steps, and logs every action for future review. No confusion. No delays. Just a clear path forward, ensuring everyone across the production team, from the field and control room operators to the production superintendent (who was previously tearing their hair out) knows exactly what to do. This is the power of data-driven decision-making. Not as a buzzword, but as a practical tool that provides clarity in a situation that would otherwise be “clear as slurry”.
Tools like digital Trigger Action Response Plans (TARPs) are reshaping how industries handle disruptions, not to replace human expertise, but to amplify their impact. By merging real-time alerts, historical insights, and collaborative workflows, these systems empower teams to act decisively to keep operations resilient, efficient, and safe.
The role of data in modern operations
Industrial operations generate vast amounts of data every second. In the mining sector, equipment sensors, production logs, and safety systems collectively contribute to this data influx. Yet, according to a BCG survey of metals and mining companies, only around 10 per cent of the industry views data as a corporate asset. An overwhelming majority of what’s collected remains underleveraged in decision-making processes. This underutilisation not only represents missed opportunities but also exposes operations to increased risks, as potential issues may go unnoticed without proper data analysis.
Data-driven decision-making bridges this gap by transforming raw numbers into actionable insights. Take a scenario where a pump in a processing plant begins acting abnormally. Without real-time analytics, operators might overlook the warning until a breakdown occurs.
With systems like digital Trigger Action Response Plans (TARPs), deviations trigger instant alerts, predefined corrective actions, and automated logging. This approach slashes response times, reduces human error, and empowers less experienced staff to follow best-practice protocols.
Reducing variability with predefined responses
Feed variability is par for the course in the MMM sector, however effective response and management however effective response and management of the downstream impacts of the input variation is key to maintaining efficiency and uptime. A single unplanned stoppage can spiral into hours of downtime, costing on average $187,500 per hour in the mining and metals sector, according to a MarketScale analysis.
Digital TARPs tackle this challenge head-on by providing structured, standardised responses to critical production events, ensuring consistency across crews, regardless of experience levels.
Enhancing risk management through historical insights
Past failures hold the key to future success if the teams can learn from them. Digital TARPs succeed here by capturing granular details of every event, including actions taken, outcomes, or even ad-hoc recommendations. With the beauty of (recorded) hindsight, teams can gain insight from the data to uncover patterns to further improve their risk management strategies. Historical insights turn reactive fixes into proactive strategies.
Real-time collaboration for faster resolution
In high-pressure environments, miscommunication is costly. Don’t let the bystander effect delay responding or duplicating efforts. Digital TARPs eliminate this friction by providing a centralised, real-time platform where each stakeholder has clearly defined actions as the situation escalates.
Everyone sees the same dashboard highlighting the current situation, timeline of event risk severity, assigned actions, and progress updates. No more scribbled notes, trial and error, or gut-feel remedies. Just aligned, efficient teamwork.
Building a culture of continuous improvement
Operational resilience isn’t about surviving one crisis. It’s about evolving through every challenge. Digital TARPs foster this mindset by maintaining detailed audit trails that teams can review, refine, and reuse. Lessons learned become part of a living knowledge base.
According to AMC Consultants, mining operations that integrate data analytics into continuous improvement programs see productivity gains of up to 30 per cent in drilling and 20 per cent in loading and hauling compared to peers using traditional methods.
The future of operational resilience
The rise of Industry 4.0 technologies like IoT sensors, AI-driven analytics, and predictive maintenance tools is reshaping industrial operations. But these advancements only deliver value when paired with human expertise. Digital TARPs sit at this intersection, translating data floods into clear, actionable steps.
For operations specialists, this means fewer 2 A.M. crises and more strategic wins. For control systems operators, it means confidence in every decision. And for metallurgists, it means smoother processes and safer workplaces. The message is clear: data isn’t replacing people. It’s empowering them to work smarter, faster, and safer.
Discover Digital TARP
Read more about Mipac's software
In the mining, minerals and metals (MMM) industry, downtime remains one of the most costly and disruptive challenges. With operations running 24 …
Ok Tedi, PNG’s longest-running open-pit mine, faced challenges including declining ore grades, operational instability, and diminished trust in process control systems. In …
Short Interval Control (SIC) has emerged as a powerful method to drive continuous improvement in mining operations. By enabling real-time decision-making and …