BHP has lifted productivity across its Western Australian Iron Ore operations after resolving a key mechanical constraint in its haulage fleet. The improvement has unlocked tens of millions of dollars in annual revenue at WAIO.
The company now transports an additional 1.52 million tonnes of iron ore each year. That equates to around 127,000 extra tonnes per month. This gain strengthens output from one of Australia’s most significant iron ore operations.
The productivity uplift followed a targeted upgrade to haul truck hoist cylinders. The redesign allows truck trays to tip at a higher angle, improving material discharge during dumping.
Solving a Hydraulic Limitation at South Flank
Engineers at the South Flank mine identified a hydraulic restriction that limited tray movement. The existing cylinders prevented haul truck trays from reaching the optimal tipping angle.
As a result, ore frequently remained stuck in the tray after dumping. This issue, known as carry-back, reduced haul truck productivity and disrupted material flow.
The operations team developed a technical solution to address the constraint. They partnered with Chinese manufacturer JC Cylinders to design and produce customised hoist cylinders.
The new hydraulic cylinders enable a steeper tipping angle. This adjustment ensures more complete load discharge during each cycle.
Following installation, BHP reduced carry-back incidents by 54 per cent. The improvement directly increased haul truck efficiency and iron ore throughput.
Haul Truck Productivity Drives Revenue Growth
The hardware upgrade delivered immediate operational benefits across WAIO. By reducing carry-back, BHP improved cycle times and increased effective payload movement.
“These bespoke cylinder hoists have been a tipping point for haul truck productivity, resulting in a 54 per cent reduction in the number of times product is carried back in the truck,” BHP group procurement officer Rashpal Bhatti said.
The mechanical optimisation demonstrates how targeted engineering changes can unlock significant production gains in mining operations.
“It’s a small solution with a big impact,” Bhatti said “We see every dollar we spend as a lever for performance and progress.”
The project highlights how incremental innovation can generate substantial value in bulk commodity production.
Procurement and Innovation in Mining Operations
Rashpal Bhatti, who oversees BHP’s global procurement spend from Adelaide, emphasised the strategic value of the initiative. He noted that procurement scale can accelerate technical innovation across the mining supply chain.
By leveraging supplier partnerships and engineering expertise, BHP delivered a cost-effective solution to a fleet-wide limitation.
The WAIO haul truck upgrade shows how mining companies can improve operational efficiency without large-scale capital expansion. Strategic equipment upgrades, data-driven problem solving and supplier collaboration remain critical to iron ore production performance.
For Western Australian iron ore producers, optimising haulage systems continues to play a vital role in maximising output and maintaining global competitiveness.
