Why do so many mining plans fail to deliver on their promises?
It’s a question that keeps mining executives, consultants, and engineers up at night. Feasibility studies look solid on paper. Capital budgets get approved. Fleets are ordered. Construction begins.
Then reality hits.
Production targets slip. Bottlenecks emerge that no one predicted. Equipment sits idle while other areas are starved for capacity. The plan that looked so promising in the spreadsheet starts breaking down the moment it meets the complexity of actual operations.
The root cause? Most mining plans are built on averages: average cycle times, average utilization, average availability. But real mines don’t run on averages. They’re variable, congested, and deeply interconnected systems where a delay in one area ripples through everything else.
The Cost of Getting It Wrong
The consequences of average-based planning are serious:
- Oversized fleets that tie up tens of millions in unnecessary CAPEX
- Undersized fleets that can’t meet production targets
- Hidden bottlenecks that erode NPV and ROI
- Misaligned expectations between planning, operations, and finance
- Lost flexibility once capital is committed
A single fleet sizing mistake can cost $50 million or more. Multiply that across multiple decisions over a mine’s life, and the financial impact becomes staggering.
But here’s the challenge: you can’t trial a new fleet configuration or mine layout in the real world without committing capital first. Or can you?
Enter Simulation-Based Digital Twins
What if you could test every major planning and operational decision before it happens? What if you could see exactly how your mine will behave under real constraints, variability, congestion, equipment failures, crew scheduling, before spending a single dollar on capital?
That’s exactly what simulation-based digital twins make possible.
Unlike traditional planning tools that assume smooth, linear flow, simulation models capture how mining systems actually work: drill-blast-load-haul cycles that share equipment, compete for resources, and interact in complex ways. It accounts for queuing, sequencing rules, maintenance schedules, and all the messy realities that static spreadsheets ignore.
Introducing MineTwin: Purpose-Built for Mining
We’re excited to invite you to an upcoming webinar on MineTwin, a simulation-based digital twin designed specifically for underground and open-pit mining operations.
MineTwin combines discrete-event simulation, scheduling, and optimization to help mining consultants, engineers, and operations leaders:
✓ Test mine plans under realistic conditions before committing capital
✓ Right-size fleets and optimize capital allocation based on actual system behavior
✓ Identify real bottlenecks hidden in equipment interactions and constraints
✓ Evaluate new technologies like automation and electrification
✓ Accelerate feasibility studies by weeks while improving confidence
✓ Build defensible investment cases with quantified ROI under realistic scenarios
Real Results from Real Mines
The impact of simulation-based planning isn’t theoretical. Consider these examples:
Nornickel applied MineTwin across six underground mines to right-size fleets, rebalance resources, and evaluate CAPEX initiatives. The result? $262 million in cost savings and an ROI exceeding 800%. But perhaps more importantly, they built an internal MineTwin competence center that transformed their decision-making from intuition-based to simulation-backed.
In another case, an open-pit operation used MineTwin to challenge the assumption that bigger is always better in haulage. By modeling variability, queuing, and truck-shovel interactions, they discovered that smaller 40-ton autonomous trucks outperformed larger 100-ton trucks—increasing NPV by 31% compared to manned trucks. Simulation made this opportunity visible before capital was committed.
Who Should Attend This Webinar?
This session is designed for:
- Mining consultants conducting feasibility studies and capital planning
- Mine planners converting geology into viable long-term mine plans
- Schedulers translating plans into executable sequences
- Mine managers responsible for delivering production safely and profitably
- Engineering leaders evaluating CAPEX investments and new technology
- Operations professionals seeking to optimize existing assets
Whether you’re in prefeasibility, expansion planning, or struggling with underperforming operations, you’ll see how MineTwin applies across the entire mine life cycle.
What You’ll Learn
During this practical, example-driven webinar, our presenters will walk you through:
How MineTwin Works
- The three complementary modes: Design, Simulation, and Study
- How to build a digital mine that reflects real operational constraints
- Running structured experiments to answer specific decision questions
- Interpreting results and translating them into actionable recommendations
Where MineTwin Adds Value
- Greenfield development and prefeasibility studies
- Brownfield expansion and debottlenecking
- Fleet optimization and CAPEX justification
- Technology evaluation (autonomy, electrification, etc.)
- Life-of-mine risk analysis and sensitivity testing
Real-World Applications
Through case studies and demonstrations, you’ll see exactly how simulation bridges the gap between planning and reality, turning strategy into achievable, defensible performance.
Meet Your Presenters
Gerda Trollip, P.Eng.
Gerda is a Professional Industrial Engineer specializing in discrete event simulation modeling for mining and mineral processing operations. Since 2009, she has applied advanced simulation techniques across the full project lifecycle—from feasibility through operations—to identify system constraints, optimize capital decisions, and drive operational improvements. With hands-on experience at major mine sites and consulting engineering firms, Gerda holds B.Eng and B.Eng (Hons) degrees in Industrial Engineering from the University of Pretoria and is licensed with Professional Engineers Ontario.
Martin M. Franklin, PMP
Martin is an international consultant specializing in advanced analytical tools and dynamic simulation for complex decision-making environments. With expertise across multiple modeling platforms, he has applied simulation methodologies in industries ranging from mining and manufacturing to healthcare, logistics, and pharmaceuticals. Martin holds an MBA from Georgetown University’s McDonough School of Business (Beta Gamma Sigma Honors), dual Industrial Engineering degrees from the University of Pretoria, and is a certified Project Management Professional and member of IISE.
Key Takeaways
By the end of this webinar, you’ll have:
- A clear understanding of what MineTwin is (and isn’t) and how it differs from traditional planning tools
- Practical knowledge of the types of questions MineTwin can answer across different mine life stages
- Real examples of how simulation has delivered measurable value for mining operations
- Confidence in the approach with an understanding of data requirements, model validation, and implementation considerations
- Next steps for getting started with a proof-of-concept or personalized demo
Beyond Spreadsheets: The Future of Mine Planning
The mining industry is at an inflection point. Margins are tightening. Capital is expensive. Stakeholders demand greater certainty. The old approach, planning with averages and hoping for the best, simply isn’t good enough anymore.
Digital twin technology represents a fundamental shift: from reactive problem-solving to proactive decision-making. From debating assumptions in meeting rooms to testing them in a virtual environment. From committing capital based on best guesses to making defensible choices backed by realistic simulations.
The most successful mining operations of the next decade won’t be those with the biggest fleets or the richest ore bodies. They’ll be the ones that consistently make better decisions faster, and simulation-based digital twins are how they’ll do it.
Register Today
Don’t miss this opportunity to see how MineTwin can transform your approach to mine planning and capital investment.
Register here: https://events.teams.microsoft.com/event/e2c927be-8dbd-4e82-b4a5-dc1f539e9ad5@15fef6f2-7713-4bc4-bbc8-0f95f5d26aa8
Webinar Details:
- Date: Wednesday, February 11
- Time: 3:00 PM – 4:00 PM EST
- Duration: Approximately 60 minutes including Q&A
- Cost: Free
- Format: Live online presentation with interactive Q&A
Reserve your spot today and take the first step toward turning your mining plans from hopeful projections into defensible, achievable strategies.
Questions before the webinar? Contact us here or connect with Gerda and Martin on LinkedIn.
Can’t make the live session? Register anyway and we’ll send you the recording.
Tags: Digital Twin, Mine Planning, Mining Technology, Simulation Modeling, CAPEX Optimization, Mining Consulting, MineTwin, Feasibility Studies, Mining Operations