Last Updated: 7 April 2025
"If I received every fuel saving all of these technologies have promised me over the years, my trucks would produce fuel!"
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This quote from a mine manager captures the scepticism many in the industry feel about the grand claims of fuel savings from Fleet Management Systems (FMS) and other technologies. Let's take a realistic look at how much fuel these systems actually save in a mining operation.
The Gains of Route Optimization
Route optimization is frequently touted as a major fuel-saving feature of FMS. By calculating the most efficient paths, these systems can reduce travel distances and idle times. However, the actual fuel savings from optimized routes are often marginal because there are usually limited routes between points in a mine, and operators typically avoid inefficient paths. While every bit helps, the reduction in fuel consumption from route optimization alone is not going to revolutionize your fuel budget or carbon footprint.
Equipment Allocation: Fewer Trucks, Less Fuel?
Another potential benefit of FMS is optimizing equipment allocation. In theory, hitting production targets with fewer trucks should save fuel. But in practice, the savings are often more about reduced maintenance costs than significant fuel reductions. Parking a few trucks might lower fuel usage slightly, but the real benefit comes from less wear and tear on the equipment and long-term asset costs.
The Reality of Fuel Dispatch
Wenco’s Fuel Dispatch system does exactly that - it dispatches mobile equipment to fuel at the right time, rather than on a fixed schedule. This approach can indeed save some fuel by reducing unnecessary downtime and does reduce total monthly off-route miles for fuelling operations. Yet again, the fuel savings are incremental. It's a smart practice and makes a big impact on your equipment availability, but not a game-changer in terms of fuel consumption. The real benefit of fuel dispatch lies in the improved equipment availability for production by fuelling only when needed.
The Bigger Picture: Marginal Gains Add Up
While each of these strategies—route optimization, equipment allocation, and timely fuel dispatch—offers measurable fuel savings on its own, together they contribute to a more efficient operation. These small gains do add up, helping to improve your ESG footprint and operational efficiency.
Beyond Fuel Savings: The Real Value of FMS
The primary reason to invest in an FMS is not just to save fuel. The real value lies in optimizing production operations, tracking production, and enabling analytics. Fuel savings are a secondary benefit. An FMS helps streamline operations, reduce idle times, and ensure that equipment is used effectively, which can lead to more productive mining activities.
Side Note: Reducing Extended Periods of Engine Idle Time
Wenco's Readyline solution, while strictly not part of an FMS which is the topic of this article, has demonstrably achieved significant fuel savings. By monitoring engine idle time using engine RPM, ignition, and GPS data, operations teams can identify and address prolonged periods of idling. A Wenco client in North America, for example, realized over $1 million in fuel savings thanks to Readyline's engine idle detection module.
Final Thoughts
While Fleet Management Systems may not deliver dramatic fuel savings on their own, they significantly streamline fuel-related processes in a mine. Although these systems may not always result in substantial savings, they offer realistic and achievable improvements. The bulk of fuel consumption is determined by the machine, operator behavior, and environmental conditions such as slope and road quality. Optimizing fuel usage outside of travel routes has a smaller impact compared to the travel itself. The true value of an FMS lies in its ability to optimize production, track performance, and enable detailed analytics. By focusing on these broader benefits, mining operations can achieve significant gains that extend beyond just fuel savings. At Wenco, we believe in setting realistic expectations and delivering tangible improvements that help our clients succeed in a competitive industry.
Published: 7 April 2025
Last Updated: 7 April 2025