Description

Fatigue remains one of the most pervasive and underestimated contributors to risk in surface mining. Conventional controls, including shift design, self-reporting, and supervisor observation, provide limited insight into real-time cognitive impairment, particularly during circadian low points between 2:00-5:00AM. This presentation examines how an EEG-based wearable (SmartCap) has been deployed across multiple global mine sites to quantify operator alertness, identify fatigue hotspots, and support operational decision-making in 24/7 mining environments.

Drawing from aggregated, non-identifiable datasets from operations in North America, Latin America, Africa, and Australasia, this work evaluates fatigue prevalence across shift types, seasons, and equipment groups. The analysis includes alertness profiles from haul truck, dozer, and shovel operators; correlations between EEG-derived fatigue risk levels and operational patterns; and the impact of circadian troughs, extended night shifts, and heat exposure on cognitive performance. The presentation will highlight practical implementation lessons from operator onboarding, union engagement, privacy considerations, and integration with fleet management systems.

Results show consistent fatigue elevation between late-night and early-morning hours, with identifiable spikes influenced by roster design and task monotony. Sites using real-time neurotechnology-driven interventions, such as break optimization, supervisor notifications, and targeted shift redesign, demonstrated measurable reductions in high-risk fatigue events within the first three months. Critical success factors included transparent communication, cross-functional governance, and clear protocols for responding to elevated fatigue scores.

This session provides mine operators and safety leaders with actionable findings on how neurotechnology can strengthen fatigue management systems, improve situational awareness, and reduce risk in continuous mining operations. The insights presented are grounded in field implementation, emphasizing what works, what does not, and how mines can responsibly leverage physiological monitoring to protect workers and maintain safe production