Case Study: Bengalla Mining Company achieves 100k+ ton production gain and real-time operational control with Hitachi Vantara Lumada

Bengalla Mining Company finds Big Productivity Gains in Incremental Improvements with Lumada

Bengalla Mining Company (BMC), a large thermal-coal producer in New South Wales, faced the challenge of turning disparate operational data—from more than 12,500 SCADA and sensor points—into real-time, usable insights to reduce operator variance, prevent unplanned slowdowns and increase production without a costly plant expansion. BMC engaged Hitachi Vantara to design an “ingest and analyze” approach that would deliver actionable alerts and analytics to technicians on the shop-floor and in the control room.

Hitachi Vantara implemented a Lumada-based solution combining Lumada Manufacturing Insights, Lumada Maintenance Insights, Pentaho Data Integration and the Hitachi Unified Compute Platform HC to ingest plant and fleet data, apply analytics and surface best-practice guidance to operators. The Hitachi Vantara deployment produced measurable impact—over 100,000 additional tons produced in the first 12 months, earlier prediction of production issues, fewer shutdowns and consistently reduced operator variance—allowing BMC to boost throughput and defer a multi‑hundred‑million dollar expansion.

Bengalla Mining Company

Kent Flaherty

Electrical Engineering Superintendent