IBM Maximo for Mining & Metals
Haul truck meters, component rebuilds, OEM telematics, and MSHA inspection records on IBM Maximo Application Suite, configured for mines
Overview
IBM does not sell a Maximo for Mining product. Its Manage industry solutions cover aviation, civil infrastructure, nuclear, oil and gas, renewables, transportation, and utilities, so mines run core Maximo Manage configured for heavy mobile equipment and fixed plant. That configuration is where results are won or lost: continuous meters for SMU-hour PMs, rotating items for engine, transmission, and final drive rebuilds, serialized tires, and inspection forms for pre-shift checks that crews complete offline in Maximo Mobile. OEM telematics from Caterpillar and Komatsu reach Maximo through integration, not a native connector, while Maximo Monitor's Edge Data Collector pulls PLC and SCADA data from crushers, mills, and conveyors for Health and Predict. We design that architecture, connect defect findings to work orders and tag-out, and keep inspection records retrievable when an MSHA inspector asks for them.
What mining & metals maintenance leaders are prioritizing
Mining product names that changed
Maximo Safety was withdrawn in MAS 8.9; the current product is Maximo Health, Safety and Environment. Maximo Assist was renamed Maximo Collaborate in MAS 9.1 and became a Manage add-on in MAS 9.2; it is remote expert collaboration, not offline AI troubleshooting. MRO Inventory Optimization is now Maximo Inventory Optimization, and Maximo Mobile has replaced Maximo Anywhere.
The problem
39% of 2025 us mining deaths from powered haulage. 13 of the nation's 33 mining fatalities in 2025 were powered haulage accidents
2,862 moving machine parts violations, 2025. 30 CFR 56.14107(a), MSHA's most frequently cited standard in 2025
2,244 safety defect violations, 2025. 30 CFR 56.14100(b), examination, correction and records of equipment defects
Powered haulage is the largest single cause of US mining deaths in MSHA data, so mobile equipment defects must be found, fixed, and recorded before machines run.
Haul trucks and loaders wear by engine hours and payload cycles, not calendar days. Calendar PMs either waste labor or miss due points.
Engines, transmissions, wheel motors, and final drives move between machines, storerooms, and rebuild vendors. Without serialized history, component life and warranty claims are guesswork.
Cat and Komatsu machine data sits in OEM platforms. Getting meter readings and fault codes into the EAM takes integration middleware and alert filtering.
A failed primary crusher or overland conveyor can stop the whole processing circuit, and these assets often have PLC data that nobody uses for maintenance.
Long lead times to remote mines push sites to overstock some spares and run short of others.
How we fix it
Continuous meters on SMU or engine hours drive meter-based PMs and Master PMs, and gauge meters on temperatures and pressures can trigger condition-monitoring work orders when limits are crossed.
AI in practice
Meter readings from telematics or operator entry roll PM due points forward automatically, so work is planned on actual usage.
Rebuildable components and tires are set up as rotating items whose units are individual serialized assets, moving between the machine, the storeroom, and an external repair vendor with full history. Item assembly structures describe what each component contains.
AI in practice
Component history supports life-to-failure reporting by component, model, and site.
Caterpillar Product Link Elite data streaming into an AVEVA PI System, and Komatsu's ISO 15143-3 API, can feed Maximo Monitor or Manage meters through middleware. Edge Data Collector pulls OPC UA and Modbus data from crushers, mills, and conveyors.
AI in practice
Maximo Health scores condition and risk, and Maximo Predict estimates failure probability for bottleneck fixed-plant assets. Fault-code severity routing can be configured to avoid alert floods.
Manage inspection forms run on Maximo Mobile offline for pre-shift and workplace examinations. A defect creates a work order and tag-out status, and the record stays retrievable. Maximo Health, Safety and Environment adds incidents, permits, and management of change.
AI in practice
Uncorrected defects stay visible on the asset until the corrective work order is closed.
Maximo Inventory Optimization models stocking levels against service targets across sites. Reliability Strategies, included in Manage, provides FMEA and RCM content for mobile equipment and fixed plant.
AI in practice
Recommended reorder points can be written back to the Maximo item master so stocking reflects real demand.
Walk through your assets, integrations, and compliance needs with an engineer who has configured Maximo for your industry.
The platform
Compliance
Surface and underground metal/nonmetal standards, including 56.14100 safety defects. Maximo Mobile pre-shift inspections, defect-to-work-order flow, tag-out status, and retained defect records support them.
Inspection forms and routes keep examination results on record and retrievable.
The asset register of mobile equipment, hazard records in Maximo HSE, and recurring program review tasks provide evidence for the written safety program.
30 CFR Part 50 Accident and Injury Reporting
HSE incident records can serve as source data. Maximo has no documented MSHA report generator.
Asset hierarchy, criticality, lifecycle cost, and Health scoring support an ISO 55001 asset management system.
Maximo HSE incidents, risk assessments, and management of change support an ISO 45001 system.
Environmental compliance tasks in HSE and reclamation work as projects. SMCRA applies to coal mining only.
No. IBM's Manage industry solutions are Aviation, Civil Infrastructure, Nuclear, Oil & Gas, Renewables, Transportation, and Utilities, and none is mining-specific. Mines run core Maximo Manage configured for heavy mobile equipment and fixed plant, plus add-ons such as HSE, Monitor, Health, and Predict.
Define a continuous meter such as SMU or engine hours on the asset and create a meter-based PM or Master PM frequency. Readings from telematics or operator entry roll the PM due point forward, and gauge meters can trigger condition-monitoring work orders when limits are crossed.
Rebuildable components such as engines, transmissions, and final drives are set up as rotating items whose units are individual serialized assets. They move between the machine, the storeroom, and an external repair location with full history, and item assembly structures describe what each component contains.
Not out of the box. Caterpillar exposes data through Product Link Elite data streaming into an AVEVA PI System and through VIMS Telemetry, and Komatsu offers the ISO 15143-3 API. These feed Maximo Monitor or Manage meters through integration middleware.
30 CFR 56.14100 and 57.14100 require operators to inspect self-propelled mobile equipment before each shift, correct safety defects in a timely manner, tag out hazardous equipment, and record uncorrected defects until they are fixed. 56.14100(b) was MSHA's sixth most-cited standard in 2025.
A final rule published in December 2023 requires surface mines and surface areas of underground mines to have a written safety program for surface mobile equipment. The program must be evaluated at least annually.
Powered haulage. MSHA reports that powered haulage accidents accounted for 13 of the nation's 33 mining fatalities in 2025.
All three are used by large miners. Ellipse, now with Hitachi Energy, is strong in Australian mining, SAP is common where SAP is the ERP, and Maximo is chosen for configurability, asset performance management, and IoT. No public source gives reliable mining market shares.
Yes. Maximo Mobile, which replaced Maximo Anywhere, supports disconnected work execution and syncs when the device reconnects. Specific inspection and meter-entry flows should be validated in a pilot.
Fixed-plant assets with PLC or SCADA data are the easiest place to start. Edge Data Collector can pull OPC UA or Modbus data into Maximo Monitor, and Health and Predict score failure risk, so start with one bottleneck asset class such as the primary crusher.
Tell us where your maintenance program is today. We will tell you honestly what Maximo can and cannot do for it.
