THE SOLUTION

A robust, enterprise-grade Integrated Mine Management Information System was rapidly built using Devum low-code application platform, consolidating operational data across 27 bauxite mining leases in four states. The solution unified land acquisition, drilling, hauling, crushing, stockyard, dispatch, and HSE operations into a single digital platform. Using Devum App Studio, Devum KPI Builder, Map Controls, and Devum Domain Services the team developed GIS-enabled dashboards for land and lease tracking, real-time monitoring of equipment and processes, and centralised reporting with automated updates. Offline-first capabilities ensured continuous data capture, even in remote areas, with automatic sync when connectivity resumed.

Modules for stockpile tracking, dispatch monitoring, and contractor billing were built using Devum Workflow Builder, Devum Domain Services, and Devum REST Responder, integrating seamlessly with RFID systems, weighbridges, drone survey data, and ERP platforms. Custom microservices enabled accurate material reconciliation and performance-based contractor payouts. The rapid deployment of these systems, powered by Devum’s Microservices Framework and Devum App Studio’s visual development environment delivered full digitalisation of mine operations with minimal coding, reduced manual errors, and enabled real-time decision-making across the value chain.

CLIENT*

The end user is a leading name in the bauxite mining and aluminium production industry, headquartered in India. Established several decades ago, the company has grown into a formidable player in the sector, endowed with vast mining operations and extensive refining capabilities. The company is synonymous with innovation, sustainability, and excellence, which are reflected in its world-class facilities and cutting-edge technology.

The company holds a prominent position in the global market, supplying high-quality bauxite and aluminium products to various industries, including automotive, construction, and consumer goods. With a strong focus on sustainable mining practices and a commitment to environmental stewardship, the company has set benchmarks for eco-friendly operations and community engagement.

*All names and logos have been changed to respect the NDA.

THE PROBLEM STATEMENT

FRAGMENTED LAND DATA AND UNTRACKED MINERAL RESERVES

Managing land acquisitions and leases was challenging due to fragmented data across multiple systems. This caused delays in procurement and created compliance bottlenecks. There was no centralised system to track:

• Land already procured vs. pending acquisition
• Real-time status of land purchases and lease agreements

Additionally, the absence of a unified mineral reserve monitoring system made it difficult to track deposit locations, estimate ore grades, and maintain visibility over reserve quantities – most of which were manually recorded.

Using Devum App Studio and Map-based Visualisation Controls, a 2D GIS-enabled Land Management System was built to visualise land boundaries via polygon overlays, enabling real-time tracking of lease status across multiple mining sites. To build the orthomosaic map-based land visualisation, Devum Microservices Framework processed raw GeoTIFF files, typically received from client drone surveys by tiling and rendering them into a seamless orthomosaic layer. This composite map, combined with GeoJSON conversions of KML (Keyhole Markup Language), KMZ (KML Zipped), and SHP (Shapefile) files, enabled GIS-based lease boundary visualisation. Additionally, these Shapefiles, exported from tools like Datamine, were uploaded into Devum to deploy a Mineral Reserve Modelling System (MRMS), enabling block-level insights when users drew or selected polygons. This enhanced grade estimation and improved planning for ore blending and extraction.

MANUAL OPERATIONS MONITORING

Daily operations like drilling, blasting, hauling, and crushing were manually logged using paper forms or isolated apps, resulting in fragmented data, poor equipment utilisation, and minimal oversight.

Devum App Studio’s HTML and Map components combined with offline data capture and automatic sync features, enabled the rapid development of a Mine Operation Monitoring System (MOMS). With no onboard load sensors or connectivity in many operational zones, production data such as drilling, hauling, and crushing was recorded manually by supervisors using tablets in offline mode. Devum’s offline-first architecture ensured that this data was reliably captured on-site and automatically synced to the central system once connectivity was restored. To enhance operational visibility, Devum Map Controls and Prebuilt Geofencing components were used to visually mark activity zones — helping identify where specific operations (e.g., hauling vs. crushing) were taking place, and track area usage for stockpiling. Combined with Devum KPI Builder, the data fed real-time dashboards, enabling supervisors to monitor production metrics with greater clarity and reduced lag. 

STOCKPILE TRACKING GAPS

The company faced issues with stockpile visibility, inconsistent dispatch coordination, and lack of automated grade tracking. Geo-fencing was either missing or unreliable. 

An Integrated Stockyard Management System was built using Devum KPI Builder, and GeoJSON Loader component. With geo-tagged maps, stockpile dashboards offered live visibility and grade control. Workflows were created effortlessly through the visual interface, enabling seamless dispatch coordination and resource tracking.

INACCURATE MATERIAL RECONCILIATION

Reconciling actual mineral movement with expected stock was a manual, error-prone task. There was no automated method to track total material flow across multiple sites.

A Grade and Movement Monitoring System was built using Devum. It automated material tracking across mine and plant sites and enabled reconciliation of surveyed quantities with actual movement data. Devum’s Map-based geofencing component restricted stock movement to predefined zones, and the KPI Builder delivered live dashboards for material balance tracking, significantly reducing inconsistencies. 

MANUAL AND DELAYED REPORTING

The absence of an integrated reporting system meant that reports were manually compiled, time-consuming to generate, and often outdated. Historical data comparisons were difficult due to lack of data consolidation.

Devum App Studio, Domain Services, and KPI Builder were used to build a Centralised Reporting and Real-time Insights Platform. This included dynamic dashboards. Devum Report Scheduler automated periodic reporting, delivering accurate reports to relevant teams at scheduled intervals, thereby reducing dependency on manual effort. 

CONTRACTOR BILLING INACCURACIES

Tracking contractor performance and downtime was challenging. Billing was often based on estimates rather than actual verified work, causing delays and financial discrepancies.

A Performance-based Contractor Management System was developed using Devum App Studio’s drag-and-drop HTML and Chart controls, KPI Builder, and Domain Services. A Custom Microservice calculated equipment downtime and task completion, enabling performance-based billing and reducing disputes. 

SAFETY AND COMPLIANCE VISIBILITY GAPS

There was no dedicated digital platform for tracking HSE (Health, Safety, Environment) incidents, making proactive risk management and compliance tracking difficult.

A Safety and Sustainability Application was rapidly developed using Devum. It allowed real-time safety incident tracking and automated compliance reporting. Devum App Studio’s visual interface and live KPI dashboards ensured better transparency, while Domain Services handled logic and business rules. This significantly improved safety performance and regulatory compliance. 

INFOGRAPHIC: PROCESS FLOW DIAGRAM

Integrated Mine Management Information System - Process Flow Diagram

SCREENSHOTS

BUSINESS VALUE

 *Benefits and performance improvements are based on observed operational outcomes and internal benchmarks during and after deployment. Results may vary depending on site conditions and implementation scope.

By leveraging Reactore’s powerful low-code development platform, Devum, Bharat Bauxite successfully implemented a comprehensive, scalable, and efficient digital mine management solution. What once required months of development was delivered in weeks, enabling higher operational efficiency, safer practices, and improved sustainability.

Devum makes it easy to build bespoke enterprise-grade mining digitalisation applications – fast, without complexity.