Operational systems for mines, quarries and heavy industry
A mine or a quarry runs on physical events — a load tipped, a contractor through the turnstile, a bowser draw, a truck leaving for the border — and most are written down hours later, if at all. We close that gap using the cameras, weighbridge, gate hardware and trackers already on your site, because the losses sit in the joints between systems rather than in the machinery. The result is a month-end you can defend, with variances raised while somebody can still act.
Material accounting from face to customer
We link the points where material changes hands: loader and tip counts read from cameras, weighbridge in and out, stockpile movements, dispatch notes and the receipt at the far end. When tonnes leaving the gate do not match tonnes invoiced, or a truck's laden weight sits outside its usual pattern, the variance is raised the same day with the ticket, the time and a still image attached.
A contractor-heavy workforce, counted properly
Mining and construction sites run on labour that changes weekly. Face or card readers at the gate and lamp room create a time record per person, checked against the induction and medical status held for them, so an uninducted worker is stopped at the gate instead of found in a plant area. Those hours feed payroll and contractor invoice checking directly, ending the weekly reconciliation of registers that disagree.
Beyond the gate: haulage, borders and delivery proof
The load is only half sold when it leaves the weighbridge. Vehicle tracking and geofences at the plant, the border post and the destination give a live position on every consignment moving towards Beitbridge, Chirundu, Forbes or Beira, and flag standing time before the customer phones to ask. Drivers send delivery notes and fuel slips as photographs over WhatsApp; the system reads them, files them against the trip and chases what is missing.
Maintenance, stores and the paperwork behind them
Bluetooth Low Energy tags — small battery-powered tags fixed to an asset — follow compressors, pumps, generators and lifting gear between workshop, stores and section, so finding a tool is a lookup rather than a search of the site. Runtime hours collected from the plant trigger services automatically, and the requisitions, quotes and supplier invoices that follow are read and routed rather than retyped.
The same parts serve the rest of heavy industry
Quarries, cement and lime producers, fabricators, engineering workshops and plant hire firms share the underlying problem: work happening away from a keyboard. A quarry takes the weighbridge and dispatch layer without the underground element; a fabrication shop tracks jobs through bays with tags and vision; a plant hire business runs tracking, runtime billing and invoicing off one record.
What it covers
Live muster and access
Who is on site, who is inducted, who went underground and has not returned — held as live data, not a signature in a book at the gate.
Dispatch that reconciles
Weighbridge tickets, dispatch notes, trip data and invoices are matched automatically, and mismatches escalate with the evidence attached.
Hours straight into payroll
Gate and lamp room records become shift hours, overtime and contractor claims under rules you approve, with exceptions sent to a person to decide.
Works through an outage
Processing runs on site, so a fibre cut or a load shedding window stops neither detection nor recording; records reconcile when the link returns.
How it works
Site assessment
We walk the operation with your production, safety and finance people, agree the one or two losses worth attacking first, and record the hardware and systems already in place.
Integration
We connect cameras, gate readers, the weighbridge, trackers and your payroll or ERP. In this phase the system observes and reports only; it is not permitted to act.
Rules and guardrails
Access rules, variance thresholds, escalation paths and payroll logic are agreed, then tested against historical tickets and real footage until the alerts are worth interrupting a supervisor for.
Go live and optimise
The system takes the workflow and we review weekly at first, tuning thresholds and camera positions. A first system is typically running in about four to six weeks.
Questions buyers ask
Our site has poor connectivity. Does that rule us out?
No. Rules run on a small industrial computer at the site, so the system works through a network or power interruption and synchronises afterwards. Alerts still reach phones over the mobile network, and a failed camera or link is reported as a fault rather than passing as silence.
Do we have to replace the weighbridge or the cameras?
Usually not. Most weighbridge software exposes a database or ticket export we can read, and IP cameras with a standard stream are enough for vision work. Where a camera is badly placed, the assessment says so before you spend on hardware.
Will it work with our existing ERP and payroll?
That is the intention. We integrate through whatever the system offers — an API, a database view or a scheduled file exchange — so hours, stock movements and invoices reach the ledger you already keep. We do not ask you to move your accounting to us.
How do you handle employee and biometric data?
It stays in your environment or a tenant dedicated to you, in a location you know, with access by role and a retention period written into the agreement. Biometric enrolment is your decision; card or tag identification works where it is not appropriate.
What stops the system making a bad automatic decision?
It acts only on verified information, inside rules you approved. Anything ambiguous — an unclear plate, a variance outside the usual pattern, a face it cannot match — escalates to a person rather than being guessed at.
Book a platform briefing
Fifteen minutes with an engineer, not a sales pitch. Describe the loss you cannot pin down — dispatch variance, contractor hours, plant availability — and we will say honestly what your existing hardware can and cannot see. sales@eigenstatesystems.com or WhatsApp +263 77 636 6999.