Grader Productivity Optimisation - Hunter Valley Coal Mine

Overview

At Hunter Valley Coal Mine, Proof Engineers deployed the Grader Performance Monitor (GPM) to replace subjective reporting with verified blade-down data. The site moved from engine-hour metrics to real-time visibility of where and when graders were actually working.

Results

• +122.7% productivity increase within the first month of implementation, as measured by effective blade-down time versus total active time.
• Baseline improvement from 28% to 45% in grading productivity, demonstrating rapid impact once supervisors had objective data.
• Non-subjective data replaced engine-hour metrics with verified blade-down status, enabling true performance awareness and accountability.
• Targeted maintenance: operations shifted from scattered, non-productive movement to focused, high-value grading on sections that needed it most.

Takeaways

The "Focused vs Scattered" grading intensity maps gave site leaders a clear picture of where graders were working. With GPM, the site could prioritise high-impact areas, reduce wasted movement, and quantify productivity gains—setting a benchmark for data-driven haul road management.