Loading
myRockwellAutomation
Careers
Investors
PartnerNetwork Portal
Contact Us
Popular Resources
Compatibility & Downloads (PCDC) Knowledgebase Literature Library Lifecycle Status Learning+ Training Portal
 
Product Management
Asset Management (RAAMP) Installed Base Evaluation (IBE) My Equipment Self-Service Product Registration Repairs Service Contracts & Tickets Software Activation Software Subscriptions Sustainability Dashboard
 
Product Configuration and Selection
Advisor Bill of Materials CrossWorks Integrated Architecture Builder Product Catalog ProposalWorks Proposal Builder ProposalWorks Standards Builder Safety Automation Builder
 

 

View All Tools →

InformationInformation
This content is not available in your selected language.
Rockwell Automation logo
Products
Hardware
What's New in Hardware
Circuit & Load Protection Condition Monitoring Connection Devices Distributed Control Systems Drives Energy Monitoring Human Machine Interface (HMI) Independent Cart Technology Industrial Computers & Monitors Industrial Control Products Input/Output Modules Lighting Control
Motion Control Motor Control Network Security & Infrastructure Packaged Solutions Power Supplies Programmable Controllers Push Buttons & Signaling Devices Relays & Timers Safety Instrumented Systems Safety Products Sensors & Switches Signal Interface
Software
What's New in Software
Cloud Software
 
Design
Studio 5000 FactoryTalk Logix Echo Emulate3D Digital Twin Arena Simulation FactoryTalk Design Studio FactoryTalk Twin Studio FactoryTalk Vault
 
Analytics & Data
FactoryTalk Historian FactoryTalk Analytics FactoryTalk Analytics LogixAI FactoryTalk DataMosaix FactoryTalk Energy Manager Thingworx IIoT FactoryTalk Transaction Manager FactoryTalk Edge Manager Model Predictive Control
HMI
FactoryTalk View FactoryTalk Optix
 
MES
Plex MES FactoryTalk ProductionCentre FactoryTalk PharmaSuite Plex MES for Food & Beverage FactoryTalk CPGSuite Plex Quality Management System Plex Enterprise Resource Planning Plex Asset Performance Management Plex Production Monitoring Finite Scheduler FactoryTalk EIHub
 
Performance Monitoring
FactoryTalk Metrics OEE
 
Thin Client Management
ThinManager
Maintenance
Fiix CMMS FactoryTalk Analytics GuardianAI FactoryTalk AssetCentre FactoryTalk Remote Access FactoryTalk Network Manager Emonitor
 
Process
PlantPAx FactoryTalk Batch
 
Industrial Communications
FactoryTalk Linx
 
XR/Augmented Reality
Vuforia
Product Directory Allen-Bradley FactoryTalk
Services
Asset Optimization & Workforce Services
Asset Optimization Services Overview Equipment Repair Equipment Remanufacturing Repair and Inventory Agreements Integrated Service Agreements Remote Support & Monitoring Onsite & Field Services Safety Services Training Services
Cybersecurity & Network Infrastructure
Cybersecurity Industrial Network Infrastructure Pre-Engineered Network Solutions
Digital Thread
Overview
Production Automation
Overview Coordinated Drive System Solutions
Loading
LifecycleIQ Services
Solutions & Industries
Solutions
Advanced Motion & Robotics Asset Management Cybersecurity Data Operations & Analytics Digital Thread Digital Transformation Industrial Automation Control Industrial Components Networks & Infrastructure On-Machine Solutions
Packaged Solutions Process Solutions Production Automation Production Operations Management Safety Solutions  Scalable Control & Visualization Smart Manufacturing Sustainable Solutions Workforce Enablement
 
Solutions for
OEMs
Industries
Automotive & Tire Cement Chemical Entertainment Fiber & Textiles Food & Beverage Household & Personal Care Hydrogen Infrastructure Life Sciences
Marine Metals Mining Oil & Gas Power Generation Print & Publishing Pulp & Paper Semiconductor Warehouse & Fulfillment Water Wastewater
Loading
View Case Studies
Support
Documentation
Technical Documentation Center Product Drawings & Wiring Diagrams Product Certifications Release Notes Technical Specifications
Product Support
Downloads Selection & Configuration Management
Training
Webinars Workforce Development Training Instructor-led Courses Certificate Programs Job Aids Training Workstations Learning+ Training Subscriptions
Contact Us
TechConnect Support Customer Care Software Portal Help General Inquiries
TechConnect Support
TechConnect Support

Get the knowledge and assistance for solving your technical challenges.

Learn More about TechConnect
Compatibility and Downloads (PCDC) Knowledgebase Literature Library Engage Online Community
Sales & Partners
Find a Partner
Go to the Partner Finder
 
Our PartnerNetwork
PartnerNetwork Program Digital Partners Distributor Partners Licensed Developers
Original Equipment Manufacturer (OEM) Partners Strategic Alliance Partners System Integrator Partners Technology Partners
Order Online
Software Subscriptions E-learning Training Instructor-led Training Learning+ Training Subscriptions
What is the PartnerNetwork™?
What is the PartnerNetwork™?

Our Rockwell Automation PartnerNetwork™ program gives our customers access to the best people, products, services and solutions to meet manufacturing goals and bring The Connected Enterprise to life.

Explore Now
myRockwellAutomation
Careers
Investors
PartnerNetwork Portal
Contact Us
Resources
Popular Resources
Compatibility & Downloads (PCDC) Knowledgebase Literature Library Lifecycle Status Learning+ Training Portal
 
Product Management
Asset Management (RAAMP) Installed Base Evaluation (IBE) My Equipment Self-Service Product Registration Repairs Service Contracts & Tickets Software Activation Software Subscriptions Sustainability Dashboard
 
Product Configuration and Selection
Advisor Bill of Materials CrossWorks Integrated Architecture Builder Product Catalog ProposalWorks Proposal Builder ProposalWorks Standards Builder Safety Automation Builder
 

 

View All Tools →

Select country or region
  • Argentina
  • Australia
  • Belgique | Belgium
  • Brasil
  • Canada
  • Colombia
  • Czech Republic
  • Denmark
  • Deutschland
  • España
  • Finland
  • France
  • Hungary
  • India
  • Indonesia
  • Ireland
  • Israel
  • Italia
  • México
  • Netherlands
  • New Zealand
  • Norway
  • Poland
  • Portugal
  • Puerto Rico
  • Romania
  • Russia
  • Schweiz | Suisse
  • Singapore
  • South Africa
  • Sweden
  • Turkey
  • Ukraine
  • United Arab Emirates
  • United Kingdom
  • United States
  • Österreich
  • 中国
  • 台灣, 中國
  • 日本
  • 한국
Select language
  • Deutsch
  • English
  • Español
  • Français
  • Italiano
  • Português
  • 日本語
  • 简体中文
  • 繁體中文
  • 한국어
Sign In Create an Account
Why Create an Account?
Create bills of materials, submit repair quotes, register products and more!

Manage your e-communication subscription preferences.

Manage your user profile.
Welcome, {0}
Residing Location
My Account Sign Out
Your recent searches
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
All
Products
Documents
Downloads
Suggested search terms
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
Results for "{0}"
View all results
Product results for "{0}"
Product Image
Product Image
Product Image
View all product results
Document results for "{0}"
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
View all document results
Download results for "{0}"
DownloadDownload
Catalog Numbers:
DownloadDownload
Catalog Numbers:
DownloadDownload
Catalog Numbers:
View all download results
Case Study | Digital Transformation Thought Leadership
Recent ActivityRecent Activity
3 minute read

Metso: Achieving the Autonomous Mine Starts with IIoT

AI-driven predictive maintenance and asset optimization has proven to help minerals processing plant eliminate hundreds of thousands of dollars in unnecessary spend.

Share This:

LinkedInLinkedIn
XX
FacebookFacebook
PrintPrint
EmailEmail
Aerial image of mining site at dusk

As a frontrunner in sustainable minerals processing technologies, Helsinki-based Metso

works with complex industrial customers across the globe.

Aggregates, mining, metals refining and recycling customers all rely on Metso for equipment, technology and services that improve production processes and reduce risk.

Within mining, one long-term goal is to shift to complete autonomous operations. But to get there, Metso recognized that organizations must start with the basics, creating IIoT-driven connectivity and visibility for predictive maintenance and asset optimization.

Video Player
Chevron DownChevron Down Chevron DownChevron Down
Metso Creating the Autonomous Plant
00:00
00:00
00:00
Use Up/Down Arrow keys to increase or decrease volume.

Identifying areas of opportunity

Compared to similar industries like oil and gas, mining has traditionally been plagued by low utilization of fixed assets, poor energy efficiency and high levels of downtime. This has required a less efficient hands-on approach using on-site workers for equipment and systems monitoring, maintenance and reporting.  

Metso set out to help mines move closer to the goal of autonomous mining by creating an IIoT-driven solution for predictive maintenance and asset optimization for minerals processing equipment. The result, Metso Metrics for Mining, helps achieve consistently high productivity from existing assets and helps avoid costly equipment failure and downtime.

Metso Metrics addresses the low overall equipment effectiveness (OEE) of minerals processing equipment by reducing unplanned downtime and improving the predictability and accuracy of maintenance activities. It also optimizes performance of equipment leading to improved operational and energy efficiency.

Leveraging the power of artificial and human intelligence

Metso Metrics works by connecting with PLCs and IIoT devices on critical equipment. It collects data from equipment sensors and sends it securely into the cloud. It then runs advanced AI algorithms on the data to detect new or known failure patterns and alerts managers when the data indicates a potential problem.

At one Australian mine site for iron ore, Metso Metrics looks for known failure patterns and anomalies in the data on the mine’s crushers, helping them predict incidents, proactively apply maintenance and avoid downtime.

“We’ve developed algorithms for multiple subsystems for this customer including the drive and hydraulic system, and we are tracking data on vibration patterns, oil filter and bushing health,” said Jani Puroranta, chief digital officer, Metso. “In one case, the vibration patterns indicated a problematic pattern in one specific area of the crusher. When our services team asked the on-site maintenance team to evaluate, they found an easy-to-fix loosened structure. Had this not been flagged and fixed, it had the potential to cause a catastrophic event, with potential costs of more than $1 million.”

Each of the machine algorithms is trained for 4-6 weeks on the specific machine behaviors to set a foundation for optimal performance. Then in live mode, they monitor 24/7 to detect and forecast potential failures or concerns.  

“AI is not enough. We also need human intelligence,” added Puroranta. “There’s always room for optimization, so we established performance centers staffed with expert data scientists.”

These remote teams in Santiago, Chile, and Changsha, China, look at signals coming in from machines, and interpret data to help guide customer action and provide counsel on performance optimization – even when no issues are detected. They are responsible for managing cases that require immediate action and coordinate maintenance with local on-site teams. Metso subject matter experts also use the information to support customers remotely from Metso offices across the world.

Successes to date

Early estimates and installations indicate that the biggest benefit for mineral processing plants comes from avoiding incidents and related maintenance costs, including the cost of downtime.

More than 10 mines worldwide are already using Metso Metrics and have connected more than 1,000 pieces of IIoT equipment. Several cases of early indicators have proven to avoid hundreds of thousands of dollars in costs. And while there is investment required to set up an IIoT-enabled predictive maintenance and asset optimization system, customers can see immediate results.

For customers, Metso Metrics also offers indirect benefits. As Metso develops and launches new equipment models, data coming through the analytics is being used by Metso engineers to monitor performance of new designs in actual field conditions. The designs can then be improved based on the input to create smarter, more efficient equipment that will further benefit operations in the future.

“The information we are collecting provides invaluable insights about how customers are using our machines in the field and gives us insights that our R&D teams use to create new models more quickly, allowing us to get them to market faster,” Puroranta said.

Published December 2, 2020

Topics: Mining, Metals & Cement FactoryTalk InnovationSuite
Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

FactoryTalk InnovationSuite Simplifies Integration
Overall equipment effectiveness charts for FactoryTalk InnovationSuite software
Overview
FactoryTalk InnovationSuite Simplifies Integration

Simplify how your company manages data and makes it easier for everyone to access, understand and leverage the information they need to make decisions.

Watch Now
How to take your digital transformation journey to the next level
Female employee wearing VR headset
Brochure
How to take your digital transformation journey to the next level

A practical guide for executing digital transformation.

Download Now
Doosan Bobcat: A People-powered Digital Plant
Bobcat scooping sand from a pile on a site
Case Study
Doosan Bobcat: A People-powered Digital Plant

Employee engagement helped bring more data-driven insights to the company manufacturing facility in the Czech Republic.

Read Now
The Connected Mine: A Strategy for Success
Businessman standing outside of a glass building
Blog
The Connected Mine: A Strategy for Success

See digital initiatives through to the end in your mines with six simple but powerful steps.

Read Now
  1. Chevron LeftChevron Left United Kingdom Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Company
About Us Accessibility Careers Diversity, Ethics and Integrity Engage Online Community Investor Relations Modern Slavery Statement Sustainability Trust Center
 
News & Events
Newsroom Press Releases Automation Fair Upcoming Events
 
Trending Topics
Cybersecurity Digital Transformation Smart Manufacturing The Connected Enterprise®
 
Training
Webinars Workforce Development Training
 
PartnerNetwork
Find a Partner What is the PartnerNetwork?
 
Our Brands
Allen-Bradley FactoryTalk LifecycleIQ Services
Contact Us
TechConnect Support Customer Care General Inquiries How to Buy Report Ethical Concerns
Insights
ROKStudios Management Perspectives Results Achieved Case Studies Blogs Automation Today Podcasts
BlogRockwell Automation's Blog
FI | EN
Legal Notices
Privacy & Cookies Policy
Email Preferences
Cookie Settings
Accessibility Settings
© 2025 Rockwell Automation
United Kingdom
Please update your cookie preferences to continue.
This feature requires cookies to enhance your experience. Please update your preferences to allow for these cookies:
  • Social Media Cookies
  • Functional Cookies
  • Performance Cookies
  • Marketing Cookies
  • All Cookies
You can update your preferences at any time. For more information please see our Privacy Policy
CloseClose