| Q3Automator | Autonomous Haulage — Spence, Chile (100% fleet)Mining operations | ✅ | All 33 trucks converted to fully autonomous by March 2024, ahead of target. Spence achieved 100% autonomy in haulage operations.As of April 2026 |
| Q3Automator | Autonomous Haulage — Goonyella Riverside (BMA steelmaking coal)Steelmaking coal | ✅ | 7% annualised production hours increase, contributing to 6% increase in truck and shovel stripping volumes in FY2024.As of April 2026 |
| Q3Automator | Autonomous Haulage System (AHS) — WAIO, South Flank, Jimblebar, Newman East, Mining Area CMining operations | ✅ | Structured haul cycles delegated to machine fleet; human teams manage exceptions, virtual mine model, and system parameters from IROC. 8 deployments globally. South Flank, Jimblebar, Newman East fully autonomous. AHS fleet 20% below average haulage cost, 89% availability.As of April 2026 |
| Q3Automator | Autonomous Haulage — Escondida Norte pit, ChileMining operations | ✅ | 33 autonomous trucks + 11 autonomous drills. 30% of Escondida production. 350,000+ tonnes/day moved autonomously. One of first large-scale mines to achieve full-pit autonomy.As of April 2026 |
| Q3Automator | Autonomous Drilling — WAIO (26 rigs across 5 sites)Mining operations | ✅ | 26 rigs; managed by 32 crew members plus 1 engineer at IROC in Perth, 1,100+ km away. 479,607+ autonomous drilling hours, 25 million+ metres drilled. Epiroc Pit Viper 271 fleet order ($18M) booked Q4 2024.As of April 2026 |
| Q3Automator | Shiploader Automation — Port Hedland (8 loaders)Logistics / port | ✅ | 8 automated shiploaders remotely controlled from IROC in Perth. Load ~1,500 bulk ore carriers/year; ~280 Mt iron ore exported in 2021. >1 million tonnes/year additional production from automation. Third shiploader nearing automation completion (FY2024).As of April 2026 |
| Q6Optimiser | IROC (Integrated Remote Operations Centre) — PerthOperations technology / supply chain | ✅ | Operating since 2012, 24/7/365. Controls 4 processing hubs, 5 mining hubs, 1,330+ km rail, port facilities in Pilbara. Uses StacksOn digital tool for ore quality management. IPRO (Integrated Production and Remote Operations) team maximises inflow tonnes by optimising flow, buffers, constraints and quality across the entire supply chain. Deviation management team continuously reassesses product flow.As of April 2026 |
| Q3Automator | Process Area Set Point Optimisation (PASPO) — BMA coalMineral processing | ✅ | Rolled out across BMA sites in FY2024. Increased revenue by US$15.5 million. Caval Ridge identified opportunity to reduce density variation while maintaining on-spec train product ash. Award-winning innovation (Queensland Mining Awards 2022).As of April 2026 |
| Q5Partner | Escondida AI/digital twin — Concentrator optimisationMineral processing | ✅ | Digital twin + AI model of the SAG mill value chain (ore body knowledge + processing behaviour + operational constraints). Monthly production losses from granulometry reduced ~70% in targeted applications. Microsoft Azure ML collaboration (Azure Machine Learning + Synapse Analytics + Data Lake Storage). Operators receive hourly AI recommendations to adjust concentrator variables. US$18.9M revenue uplift from AI-assisted drill and blast optimisation in FY2024. GenAI integration allows natural-language scenario testing in multiple languages.As of April 2026 |
| Q6Optimiser | Escondida AI water/energy optimisationProcess operations | 🔶 | AI technology provides real-time options and automates corrective actions on energy anomalies. Real-time data analytics on large volumes of energy usage data. Saved >3 gigalitres of water and 118 GWh of energy since FY2022. Optimises concentrators and desalination plants automatically.As of April 2026 |
| Q3Automator | Predictive maintenance analytics — Global fleet and materials handlingMaintenance / reliability | ✅ | Predictive analytic models running across most load and haul fleets globally and materials handling systems. Maintained by a small team in the Maintenance and Engineering Centre of Excellence. Provides real-time and long-range machine health indications. At WAIO fixed plant, hundreds of gigabytes of sensor data were processed to diagnose vibration risks and identify structurally similar at-risk locations.As of April 2026 |
| Q3Automator | Computer vision — Conveyor anomaly detection (WAIO)Operations safety / reliability | ✅ | COTS cameras plus ML control systems at key conveyor, crusher, and rail loading points in Chile and WA. Alerts controllers; in some cases triggers a pre-programmed automatic conveyor stop. Prior to deployment, more than 1,000 hours of downtime occurred over 3 years; post-deployment, no major disruption events. Hundreds of thousands of metric tonnes of additional processing per year.As of April 2026 |
| Q2Tactician | Magnet Safety Dashboard (MSD) — WAIO (light vehicles and SME)Safety systems | ✅ | Integrates data from collision avoidance, distraction/alertness monitoring, and fleet management systems: 800,000+ metrics from 20,000+ devices using 60+ data point types. At Yandi, MSD delivered a 58% reduction in overall vehicle events and a 70% reduction in speeding events. Leaders receive alerts for hardware/network failures and behaviour patterns.As of April 2026 |
| Q2Tactician | Smart fatigue hard hat (Escondida truck drivers)Safety systems | 🔶 | Smart hard hat sensor technology measures brain waves to detect truck driver fatigue at Escondida, alerting to prevent accidents related to driver drowsiness.As of April 2026 |
| Q1Operator | IVMS (In-Vehicle Monitoring Systems) — BHP and BMA sitesSafety systems | ✅ | Mandatory IVMS compliance across all BHP and BMA sites from 1 July 2025. Covers driver ID, speed monitoring, journey management, fatigue management, harsh event detection, real-time tracking and alerts. Automated compliance reporting.As of April 2026 |
| Q4Weaver | Voice-to-text hazard reporting applicationSafety systems | ✅ | Mobile application allows employees to log hazards instantly in the field. Reports are auto-geotagged and linked to historical incident data, providing rapid digital risk assessment to help teams respond sooner and prioritise controls.As of April 2026 |
| Q2Tactician | Central Data Platform — Exploration geoscienceExploration technology | ✅ | Supports 52 standardised core geoscience types from 100+ years of data. Geoscientists access 4M+ drill hole cores and 9,000+ geophysical surveys through one portal, built on an open-source database for interoperability. In-house AI extraction tool processes 30,000 legacy documents in hours versus months manually. Gen AI converts unstructured records into usable datasets. Collaborations with South Africa's Council for Geoscience and the Government of Canada extend the platform.As of April 2026 |
| Q5Partner | AI-assisted exploration — Machine learning for new deposit discoveryExploration technology | 🔶 | Machine learning combined with human ingenuity to discover new copper deposits in Australia and the US. Ivanhoe Electric alliance (US$15M over 3 years): Typhoon geophysical survey system plus CGI machine learning algorithmic data inversion software. Muon tomography ongoing for subsurface scanning. BHP Xplor: 6-month accelerator programme with US$500K equity-free funding per cohort; FY2024 cohort selected 6 companies from 500+ applications.As of April 2026 |
| Q5Partner | Digital twins — Pit-to-port value chain (BMA, Copper SA, Escondida)Operations / planning | ✅ | Deployed across BMA, Copper South Australia, and Escondida to understand complex interconnected systems and enable end-to-end scenario testing before field changes. At Copper SA, the digital twin assesses water, energy, and material flows to support stable operations and reduce environmental exceedance risk. GenAI interface allows natural-language queries on model outputs. Value: >US$2 billion from digital and analytics across all AI/digital initiatives over the past 4 financial years.As of April 2026 |
| Q3Automator | S/4HANA ERP upgrade and AI-enabled procurementEnterprise systems | 🔶 | Upgraded global ERP 1SAP to S/4HANA in FY2024, used for paying people and suppliers, selling products, maintaining equipment, and reporting financial results. Singapore AI Hub focus areas include more efficient procurement processes and enhanced financial forecasts.As of April 2026 |
| Q8Explorer | Singapore Industry AI HubAI capability / enterprise-wide | 🔶 | Established May 2025. BHP AI specialists plus AI Singapore (AISG) and Enterprise Singapore partnership. Focus: solve BHP enterprise-wide challenges using AI, embed data-driven decisions and automation, support predictive maintenance, optimise resource allocation, and enhance financial forecasting. Plans for collaborations with local AI partners on business problems.As of April 2026 |
| Q8Explorer | BHP Ventures — Deep technology investmentsInnovation / exploration tech | 🔶 | Investments in SiTration (silicon membrane metal extraction), ZwitterCo (water treatment membranes), Boston Metal, Electra, and ongoing testing of leaching technologies from Jetti Resources and Ceibo.As of April 2026 |
| Q8Explorer | Think & Act Differently (TAD)Innovation management | 🔶 | De-risks a portfolio of 100+ initiatives from small-scale experiments to on-site demonstrations, focused on resource growth, especially copper, leaching, ore body knowledge, and accelerated minerals recovery. Orebody Knowledge Innovation Challenge (2025) and BHP Invent Accelerator are active programmes.As of April 2026 |
| Q2Tactician | Environmental acoustic monitoring and MLEnvironmental management | 🔶 | Acoustic monitoring detects endangered species calls; satellite and drone imagery with ML and object detection are used for weed detection. Outlier detection and pattern recognition support digital quality control.As of April 2026 |