Rising fatalities in mining continue to show traditional safety methods aren’t enough. It’s time to rethink using a digital solution to analyse risk. Leading companies are proving that streamlined, tech-driven controls can save lives and improve operations.
Why mining must evolve to tackle rising safety risks with digital solutions
The latest report from the International Council on Mining and Metals (ICMM) highlights three critical safety trends that should prompt urgent attention across the mining and metals industry:
- Worker fatalities are rising, with 36 employees at ICMM member companies tragically losing their lives in 2023, compared to 33 in 2022.
- Fatalities aren’t isolated to a single country, with failure to follow procedures identified as a leading cause.
- Total work hours across the industry are increasing, broadening the window for potential risks and near misses.
While the mining industry has historically been at the forefront of safety innovation, it’s evident there is much progress still to be made. Companies can no longer rely on manual or siloed solutions for operational safety. To advance safety measures, the industry must transition from resisting digitisation to becoming more resilient using digital solutions. Leveraging digital, connected tools will be fundamental to mitigating operational risks and enhancing safety.
That’s why it’s worth paying attention to what global mining leaders are doing to close the safety gaps — by rethinking and digitising the day-to-day processes that keep workers safe. Their approach offers a blueprint for others facing the same challenges highlighted in the ICMM report.
What a global mining leader teaches mining leaders about the importance of streamlined safety processes
A global mining leader partnered with Sphera to enhance operational safety and productivity by streamlining processes with robust digital solutions. By reducing inefficiencies and standardising workflows, the company was able to cut costs while significantly improving safety. Their approach to risk management stands out as a strong example of how digital transformation can make a real impact in high-risk environments.
Recognising ongoing gaps in high-risk work activities — even with electronic isolation systems in place — the company piloted and implemented an integrated digital permitting system in 2023.
Their primary goal: zero isolation system breaches, while also improving permit accuracy, risk assessment, communication, and control.
Upgrading from manual, paper-based permits to a digitally integrated system significantly reduced administrative errors that had previously led to isolation breaches and miscommunication. The digital solution also helped eliminate handwriting-related mistakes, ensured standardised risk assessments, and embedded critical prerequisite controls into workflows — helping to prevent failures in critical safety systems.
Results at a Glance
A global mining leader partnered with Sphera to streamline safety processes using our integrated digital permitting system—driving measurable improvements in safety, efficiency, and control.
By replacing paper-based permitting processes with digital workflows, they achieved significant improvements:
- Increased efficiency: Permit creation time was reduced from hours to minutes, expediting authorization for high-risk work.
- Fewer isolation breaches: Built-in approval protocols ensured safety measures were verified before work began.
- Enhanced visibility: The solution’s online/offline mobile application connected employees, contractors, and maintenance crews allowing area controllers to track real-time, high-risk work activities. This helped to improve oversight and surfacing additional opportunities to improve safety standards.
- Improved risk knowledge retention: Risk profiles, lessons learned and isolation records were digitized and easily accessible for future work planning and new generations of mining and metals employees.
This success highlights that prioritising safety doesn’t just benefit workers; it fosters efficiency and reinforces operational excellence.
Implementing a Safer Future: What Mining Leaders Should Look For
Despite strong belief in the value of technology—95% of process safety professionals agree it can improve outcomes—many mining organizations have yet to take meaningful steps toward transformation.
Here’s what mining companies should consider when selecting digital safety solutions:
- Industry-Specific Solutions for Complex Needs
Mining’s high-risk, complex environments demand tailored technology.
Key considerations include:
- Critical Control Checks: Digital tools should embed mandatory safeguards, reducing the risk of errors such as overlooked isolation checks.
- Mobile Safety Enhancements: Mobile-friendly dashboards displaying real-time site activities help assess hazards from equipment use and simultaneous operations (SIMOPs).
- Partnering with SMEs (Subject Matter Experts)
As experienced professionals retire, nearly half (49%) of process safety experts cite the loss of institutional knowledge as a key risk driver. Partnering with vendors that provide both technology and subject matter expertise ensures knowledge is retained and applied effectively.
Seasoned experts can support hands-on training, promote system adoption and connect legacy practices to modern platforms—ensuring continuity and safety across generations of workers.
- Scalability and Inclusivity in Risk Management
Operational safety must be embedded across all levels of the organization. However, only 29% of safety professionals rate their organization’s risk management maturity as optimized.
To increase adoption and impact:
- Involve frontline workers early in the digital transformation process
- Gather feedback to identify usability gaps and safety risks
- Provide mobile-friendly, intuitive tools that meet the expectations of digital-native employees
Engaged workers often become internal champions, accelerating implementation and fostering a culture of safety from the ground up.
Keeping mining employees safe isn’t an impossible goal
Mining operations are inherently complex, but their associated risks don’t have to be insurmountable. By integrating scalable, industry-specific digital solutions and leveraging the expertise of SMEs, mining companies can create safer, more efficient working environments.
The global mining leader’s achievements underscore an essential truth: technology isn’t an option for the mining industry. It’s the foundation for progress. By fostering innovation today, mining leaders can achieve zero fatalities tomorrow.
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