Modular Mining Systems
| Company type | Private |
|---|---|
| Industry | Mining equipment management solutions |
| Founded | 1979 |
| Founder | Dr. James Wm. White |
| Headquarters | Tucson , United States |
Area served | Worldwide (including Australia, Brazil, Canada, Chile, India, Indonesia, Mexico, Peru, Russia, South Africa, United States) |
Key people | Jorge Mascena (President and CEO) |
| Products | Fleet management software and hardware, DISPATCH Fleet Management System, DISPATCH Underground, MineCare maintenance management platform, ProVision machine guidance technology, RoadMap safety tracking solution |
| Owner | Komatsu (since 2003) |
Number of employees | 800+ |
Modular Mining is a privately owned enterprise focused on mining equipment management solutions, with its main office located in Tucson, Arizona, United States. Its premier offering, the DISPATCH Fleet Management System, is utilized at more than 250 active mining operations globally, including nine of the top ten highest-yielding surface mines.
Established in Tucson in 1979 by Dr. James Wm. White, Modular Mining created the DISPATCH system within two years—a computerized fleet management platform designed to optimize haul truck deployment and produce operational analytics for open-pit mining sites. Over time, the company has broadened its range of products to include various software and hardware tools aimed at improving mine efficiency.
In 1996, Komatsu America Corporation (KAC), a subsidiary of Komatsu based in Tokyo, acquired a majority stake in Modular Mining. By 2003, KAC had secured complete ownership, making Modular Mining a fully owned subsidiary of Komatsu. The firm operates worldwide with offices and services spanning Australia, Brazil, Canada, Chile, India, Indonesia, Mexico, Peru, Russia, South Africa, and the United States. Jorge Mascena currently leads the company as President and CEO, overseeing a workforce exceeding 800 employees globally.
The product lineup offered by Modular Mining encompasses fleet management software, maintenance tracking systems, precision machine guidance technologies, GPS monitoring devices, wireless communication hardware, centralized railway traffic control systems, and proximity detection solutions—strengthening its position and influence within the mining sector.
Initial Deployments
Between 1980 and 1981, Modular Mining partnered with Phelps Dodge Corporation (now part of Freeport-McMoRan Copper & Gold) to design and implement the inaugural DISPATCH system at the Tyrone copper mine in New Mexico. A subsequent analysis revealed a 10% boost in production efficiency. In 1985, Phelps Dodge commissioned Modular to adapt the DISPATCH system for rail logistics at its Morenci mine in Arizona and also introduced it at the El Chino mine located in New Mexico.
Expansion on a Global Scale
Following early achievements in the Southwestern United States, Modular extended its reach internationally by deploying the DISPATCH system at sites such as the Iron Ore Co. of Canada in Labrador (1985), Palabora in South Africa (1985), and the Cerrejón coal mine in Colombia (1988). To facilitate this growth, Modular launched its first overseas subsidiary—Modular Mining Systems Pty. Ltd.—in Caboolture, Australia in 1989 before relocating it to Tuggerah in 1993.
The company’s international subsidiaries were established as follows:
- 1989 – Modular Mining Systems Pty. Ltd., New South Wales, Australia
- 1993 – Modular Mining Systems, Inc. y Cia Ltda., Santiago, Chile
- 1996 – P.T. Modular Mining Systems, Balikpapan, Indonesia
- 1998 – Modular Mining Systems China, Beijing, China
- 2000 – Modular Mining System Africa Pty. Ltd., Johannesburg, South Africa
- 2000 – Modular Mining Systems do Brasil Ltda., Recife, Brazil
- 2000 – Modular Mining Systems Canada Ltd., Port Coquitlam, Canada
- 2002 – Modular Mining Systems SCRL, Lima, Peru
- 2004 – Modular Mining Systems India Pvt. Ltd., Pune, India
- 2006 – Modular Mining Systems Eurasia, Moscow, Russia
- 2009 – Modular Mining Systems do Brasil Ltda., Belo Horizonte, Brazil
Current Status of Modular Mining
Modular Mining has established itself as a frontrunner in mine management technology, with its systems supporting eight different languages globally. In October 2010, the company celebrated a significant achievement by securing its 200th client: the Moatize open-pit coal mine operated by Vale S.A. in Mozambique. This marked the third new mine that year to implement Modular’s technology from inception. Recent innovations have concentrated on enhancing machine guidance, enabling remote monitoring, and improving mine safety measures.
IntelliMine Suite Overview
Modular provides a comprehensive range of software and hardware designed to enhance mining efficiency, safety, and asset utilization. The centerpiece of their offerings is the IntelliMine integrated asset management suite, which comprises:
- The DISPATCH Fleet Management System (FMS), a leading solution for optimizing fleets in open-pit mining environments. Utilizing sophisticated algorithms such as linear and dynamic programming, it significantly decreases truck queuing times. Dispatchers centrally coordinate equipment deployment, shift rotations, refueling schedules, and downtime management through GPS-based tracking, health diagnostics, maintenance oversight, and production analytics. This real-time platform drives operational excellence and safety.
- DISPATCH Underground, introduced in 1991, remains the only fully integrated management system tailored for underground mining operations. Built with durable hardware to withstand challenging conditions, it supports all principal underground mining techniques by overseeing inventory control, material logistics, crew coordination, fleet monitoring, and personnel location tracking.
- The MineCare maintenance management platform reduces reaction times via predictive maintenance strategies and reliability-centered maintenance (RCM). It delivers essential failure diagnostics and live key performance indicators to maintenance teams. With connectivity to over 175 OEM interfaces, MineCare offers extensive condition monitoring across engines, hydraulic systems, electrical components, and tires—resulting in global reductions in maintenance expenses and equipment downtime.
- The ProVision machine guidance technology uses high-accuracy GNSS (GPS and GLONASS) to enhance operational feedback and safety while cutting costs. It supports a variety of equipment including excavators, loaders, backhoes, drills, and dozers. Safety enhancements feature Proximity Detection capabilities that warn operators of nearby machinery or hazards using GNSS data combined with onboard camera systems.
- The RoadMap position and safety tracking solution improves the safety of light vehicles within mining sites by continuously comparing GPS locations against a predefined road network. It supplies real-time situational awareness for visitors and staff through devices such as PDAs equipped with internal GPS receivers.
Autonomous Haulage Systems (AHS)
Modular Mining has played a pivotal role in Komatsu’s advancement of autonomous haulage systems. In November 2011, Rio Tinto entered into a landmark contract with Komatsu for the deployment of 150 autonomous haul trucks at its Pilbara operations in Western Australia by 2015. This agreement represented the first large-scale commercial application of autonomous haulage in mining history and was a major milestone for Modular Mining. The company provided critical elements including supervisory control systems, operational intelligence platforms, communication networks, reporting tools, and vehicle safety technologies. This implementation boosted mine productivity, enhanced safety standards, improved environmental outcomes, and generated skilled technology-focused employment opportunities.
Underground Mining Operations
In 1991, Modular Mining introduced the first-ever underground fleet management system at a diamond mine in South Africa. The DISPATCH Underground platform enhanced operational efficiency by utilizing infrared beacons to monitor equipment locations in real time and allowing operators to interact through onboard field computers installed on Load–Haul–Dump (LHD) vehicles. The information gathered was sent to a centralized server for further processing and analysis. Presently, DISPATCH Underground continues to be extensively implemented across prominent underground mining sites worldwide and underwent an update in 2016 to align with changing industry requirements.
ModularReady OEM Connectivity
Modular collaborates with all leading heavy equipment original equipment manufacturers (OEMs) within the mining sector to provide asset health monitoring via ModularReady interfaces. These connections facilitate integration between third-party systems and IntelliMine solutions, offering more than 175 interface points that supply thousands of data parameters related to payload measurement, haul cycle automation, alert notifications, and predictive trend analysis for equipment failure. This consolidated data supports centralized platforms such as MineCare, which focuses on reliability-centered maintenance (RCM), thereby improving operational productivity and maximizing machinery availability.
Enhanced Support Services
The Value Add Services (VAS) division at Modular Mining assists mining operations in enhancing their performance and maintenance strategies through tailored mine management system development and deployment for both surface and underground environments. Core services include comprehensive product training, expert consulting, business process mapping (BPM), performance benchmarking, organizational change management, and lean process implementation. Since April 2011, these change management and lean methodologies have been accessible to all clients globally, reinforcing Modular’s commitment to advancing operational effectiveness and delivering increased customer value.