Merdeka delivers measurable fleet productivity gains with Hexagon technology  

• Tujuh Bukit Gold Mine increases truck productivity by 11% and excavator productivity by 17% within six months of fleet management system adoption
• Load and haul costs fall 14%, while fuel ratio decreases 9.5% and annual CO₂ emissions are reduced by more than 3,400 tonnes
• Results build on strong technology adoption and operational collaboration, as Hexagon’s relationship with Merdeka expands to Pani Operations

PERTH, AUSTRALIA - Hexagon today announced measurable productivity, cost, and sustainability gains achieved by PT Bumi Suksesindo (BSI) at Tujuh Bukit Gold Mine in East Java, Indonesia, following the adoption of Hexagon OP Pro fleet management technology and Smart Centre consulting.

BSI, a subsidiary of PT Merdeka Copper Gold Tbk, implemented OP Pro to improve consistency in fleet productivity across shifts and provide teams with greater real-time visibility into mine activity.

Within six months, BSI increased truck productivity by 11% and excavator productivity by 17%, while reducing truck queue time by 17% and excavator hang time by 53%. Load and haul costs fell by 14%.

The operation also recorded a 9.5% reduction in fuel ratio and an annual reduction of approximately 3,405 tonnes of CO₂ emissions. High-precision GPS guidance, with loading accuracy of less than 20 centimetres, helped minimise ore loss and dilution, contributing to more than 600 ounces of additional gold recovery.

“Before implementing Hexagon, one of our biggest challenges was achieving consistent fleet productivity across shifts,” said Erik Wibisana Barnas, Technical Services Senior Manager at BSI.

OP Pro provides real-time visibility into fleet activity, production, and equipment utilisation, allowing dispatch teams to respond to changing conditions during a shift rather than relying on retrospective reporting. Its Optimiser dynamically assigns trucks based on the latest requirements of loading equipment, helping reduce unproductive time and improve fleet productivity.

Technology adoption has been central to the results. Within six months, BSI achieved more than 99% login compliance, more than 95% assignment compliance, and 90.8% Optimiser usage.

Hexagon Smart Centre consulting has complemented the technology with operational expertise, training, and continuous improvement. Hexagon specialists have worked with BSI teams to understand site-specific challenges, embed best practices, and continuously fine-tune OP Pro to reflect changing operating conditions.

“Through OP Pro and Smart Centre consulting, the focus was not only on the system implementation, but also on transferring knowledge and embedding best practices within the organisation,” said Barnas.

Dave Goddard, President of Hexagon’s Mining division, said Tujuh Bukit demonstrates the value of combining technology, data, and operational knowledge to improve everyday mining decisions.

“Fleet productivity is built on thousands of decisions made every shift,” said Goddard. “What BSI has achieved at Tujuh Bukit shows the value of making those decisions more visible, informed, and consistent. Just as importantly, the knowledge being built within the operation helps make those improvements sustainable.”

The collaboration is now extending to Merdeka’s Pani Operations, where OP Pro recently went live as part of a five-year agreement. The initial deployment includes six high-precision and 40 low-precision systems, with a further 47 low-precision truck units being processed.

The Pani deployment builds on the relationship established at Tujuh Bukit and provides an opportunity to apply the experience gained there at another Merdeka operation.

“Expanding our work with Merdeka is an important next step, but the foundation is what has already been achieved together at Tujuh Bukit,” said Goddard. “Those results provide a strong reference point as we continue working with Merdeka’s teams to improve fleet performance and build operational capability.”

Read the Tujuh Bukit customer story and watch the video here.

FOR MORE INFORMATION, CONTACT:
Neville Judd
Director, Marketing Communications
Hexagon's Mining Division
1-604-977-3943
[email protected]