MCS PRODUCTION SYSTEM

BUILT FOR Medium to Large Mining Operations

Full Visibility. Safe Production Improvement.

The MCS Production System is our flagship solution - a fully integrated platform that gives medium to large mining operations the reliable CM production information, root-cause visibility, MOS integration, and accountability structure needed to consistently improve safe production performance.

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SEE WHAT'S INCLUDED

VIS

FULL VISIBILITY

RCA

ROOT CAUSE ANALYSIS

MOS

MOS INTEGRATION

ACT

ACTION TRACKING

ACC

ACCOUNTABILITY

DIG

DIGITAL TRANSFORMATION

The Reality in Your Operation

When information is unreliable, improvement becomes impossible.

Medium to large mining operations carry significant fixed costs. In that environment, the most practical lever for profitability is producing more coal - safely. But producing more requires knowing, precisely, where time and performance are being lost.

 

no data

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Reliable CM production information is missing or inconsistent – making it impossible to accurately measure what was actually produced and when.

DOWNTIME

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CM availability and downtime data is either not captured, captured too loosely, or arrives too late to act on – leaving root causes invisible and recurring.

LOST TIME

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Inaccurate production time measurement means wasted production time hides in the gaps – unidentified, unmeasured, and therefore unfixed.

PLANNING

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Planning inefficiencies compound when there’s no reliable baseline to plan from – targets become disconnected from shift-level reality.

MOS

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Management meetings run on incorrect or contested information – spending valuable time debating “the right numbers” instead of solving real problems.

ACCOUNTABILITY

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Actions are identified but not tracked. Without a structured follow-through mechanism, the same issues resurface month after month – and improvement stalls.

 

The result? Improvement turns into a guessing game. Your MOS meetings debate the data. Your planning team works without a reliable baseline. Your section managers identify problems, but have no structured mechanism to ensure they get resolved.

Month after month, the same production losses recycle – not because your people aren’t capable, but because the system doesn’t give them what they need to succeed.

BUT IT DOES NOT NEED TO BE THIS WAY

What You're Really Looking For

Three things your operation deserves.

Behind every production challenge is a deeper set of ambitions. Here is what the operations we work with are genuinely striving toward - and what the MCS Production System is built to deliver.

Data Integrity

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One version of the truth – accurate, consistent, and trustworthy. Production information that your entire operation, from the section to the boardroom, can plan and make decisions from with confidence.
 

Asset Performance

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Your continuous miners are your most critical assets. Understanding their real availability, utilisation, and downtime patterns – with root-cause depth – is the foundation of sustained performance improvement.
 

Digital Transformation

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Moving from paper-based, manual, and fragmented reporting to a fully integrated digital production system – one that seamlessly connects to your backend infrastructure and supports scalable, repeatable ways of working.
 

Introducing the Solution

What if your operation had one integrated system that connected data, decisions, and accountability?

That is what we built the MCS Production System to be. Not a standalone reporting tool. Not another spreadsheet layer. A fully integrated, modular production system that links data integrity to daily decision-making – giving your operation the visibility, the structure, and the follow-through capability it needs to improve consistently and sustainably.

We have been monitoring and improving CM production performance since the early 2000s. We have developed a depth of CM knowledge and monitoring scale that is unmatched in the South African coal mining industry – and that knowledge is built into every aspect of this system.

The MCS Production System is not a generic technology applied to mining. It is mining expertise expressed through technology – and that distinction is what makes it work.

IMAGINE HOW IT WOULD FEEL

FROM THIS

WHERE YOU ARE NOW

Unreliable CM production information - plans built on assumptions

Downtime data missing or too vague to act on meaningfully

Wasted production time hidden in the gaps - unidentified and unfixed

Planning disconnected from real shift-level performance data

Actions identified but not tracked - same issues recycling every month.

TO THIS

WHERE YOU'RE GOING

Reliable, real-time CM production data your whole operation can trust

Full downtime visibility - categorised, analysed, and acted upon

Accurate production time measurement - wasted time identified and eliminated

Shift-level planning grounded in real data and realistic targets

MOS meetings powered by one version of the truth - focused on solutions

Every action tracked, owned, and closed - recurring losses resolved

The Platform

Built for the mining environment. Integrated by design.

The MCS Production System is a fully integrated SaaS platform. Each module is purpose-built for coal mining operations - and together they form a seamless production management system that connects your data, your people, and your decision-making.

CM Monitoring

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The heart of the system. Continuous miner monitoring captures accurate, real-time production data – availability, utilisation, and operational status – giving your operation a reliable, consistent view of performance at the section level.

Control Panel / Admin

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Your centralised production dashboard – a structured, role-appropriate view of performance data, reports, and system configuration. The right information, to the right people, at the right time.

DOWNTIME MODULE

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Digital downtime capture at source – events logged, timestamped, and categorised by shift operators. Accurate downtime data is the foundation of root-cause analysis and the key to unlocking hidden production time.
 

Planning Module

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Shift-level planning grounded in real production data. Set targets that reflect actual operational capability, translate them into simple KPIs your line managers can use, and measure performance against a credible baseline every shift.

ACTION TRACKER

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Every action identified through your MOS or root-cause process is captured here – with a clear owner, due date, and status. Accountability is built into the system, not dependent on memory or goodwill.
 

Mobile Device Access

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Section managers, supervisors, and operators can access production data, log downtime events, and update actions from mobile devices – wherever they are on site. Visibility is not confined to the office.
 
 

Shaft Audit

Every six months, the MCS team conducts a structured Shaft Audit - a comprehensive review of your section's production performance, system utilisation, and improvement trajectory. This is not a routine check-in. It is a deep, expert-led assessment that identifies emerging patterns, validates root-cause work, and recalibrates your improvement focus for the next period.

The Shaft Audit is what ensures the system stays embedded, effective, and aligned with where your operation is heading - not just where it was when implementation began.

 

Training & Support

We don't just implement. We embed.

Technology alone does not change an operation. It is the combination of the right system and the right people - embedding new ways of working at every level - that delivers lasting results. This is where MCS goes beyond a typical technology vendor.

UG

Underground Coaching Sessions

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Structured coaching delivered underground, at the section level – where production actually happens. Our team works directly with section managers and operators to embed continuous improvement habits into the daily operating rhythm. Not a once-off training event. A sustained capability-building process.
 

GM

GM & Mine Manager Coaching

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Continuous improvement must be driven from the top. We work with your General Manager and Mine Management team to embed the improvement mindset, strengthen MOS discipline, and ensure that the visibility the system creates is being used to make better strategic and operational decisions.

RCA

Root Cause Analysis Support

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Identifying root causes is a skill. Our team works alongside your section managers to build their root-cause analysis capability – so that over time, your operation develops the internal expertise to diagnose and resolve production losses independently.

CON

Consulting & Recommendations

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Every engagement includes structured consulting and a clear Project Plan – recommendations developed from your specific operational data and context, translated into a prioritised improvement roadmap. You will always know what we recommend, why we recommend it, and what the expected impact is.

Why mcs.

This is not generic technology. This is mining expertise.

The MCS Production System is built on three strategic pillars - Product, People, and Price - and it is our people and their depth of knowledge that set us apart from every other option in the market.

1

Data Integrity

Reliable, consistent production data is the foundation of everything we do. Every aspect of the system is designed to ensure the numbers you see are numbers you can trust.
2

CM Knowledge

We have been monitoring continuous miners since the early 2000s. Our understanding of CM performance, failure modes, and production patterns is unmatched.
3

Scale of Monitoring

We monitor at a scale that generates meaningful benchmarks and comparative insights - insights that a single-operation system simply cannot produce.
4

Track Record

37 years. Multiple Productivity Optimisation Projects with measurable, documented outcomes. We have a proven track record of delivering real improvement - in tonnes, in time, and in rand value.
5

Quality of People

Our team brings deep operational mining knowledge to every engagement. They understand your environment, speak your language, and have worked underground. That makes all the difference.
6

Scalability & Integration

The system scales with your operation and integrates with your backend infrastructure - giving you full Information Management capability from the section to the executive level.

Proven Results

Numbers that speak for themselves.

1 400 TPS

Before MCS Implementation

1 700 TPS

After MCS Implementation

6.4Mt

Estimated Production Improvement In One Year

+21%

Average Tonnes Per Section Increase

CASE STUDY

Section Visibility & Production Control

A group of mines was consistently failing to meet required output targets. The core challenge was production performance and section control — they lacked the visibility and short-interval control needed to identify and address recurring problems before they compounded shift after shift.

MCS introduced continuous miner monitoring across all sections, with weekly and six-weekly reporting cycles to enable short-interval control and longer-term trending. The full workforce was trained, and the MCS Production System was embedded into their daily ways of working.

MCS supported root-cause analysis across section management and coached miners throughout the transition with hands-on, on-site support — ensuring the system became part of how the operation runs, not just another tool.

THE OUTCOME

  • Clear production visibility 
  • Faster root-cause identification 
  • Fewer unplanned delays 
  • Average TPS increased from ~1,400 to ~1,700  
  • ~6.4 Mt improvement in one year
Read the Full Case Study

What Others Are Saying

Results your peers are already seeing.

General Manager
Large Coal Mining Operation, Mpumalanga

The MOS integration changed everything. We stopped debating the numbers and started solving the problems. Within three months, our section managers were running root-cause sessions independently - something that had never happened before.

Mine Manager
Medium-Scale Underground Operation

What sets MCS apart is that their people have actually worked underground. They understand what a section manager is dealing with at 5am on a night shift. That operational knowledge is built into the system â€" and you feel it from day one.

Do you have questions?

FREQUENTLY ASKED QUESTIONS

The fundamental difference is the depth of CM and mining knowledge built into the system, and the quality of the people who implement and support it. Most technology vendors understand software. We understand continuous miner production - the failure modes, the operational rhythms, the shift dynamics. That knowledge is what makes the data meaningful and the improvement sustainable.
Yes. The MCS Production System is designed for full backend integration â- connecting to your existing information management infrastructure so that production data flows seamlessly into your broader reporting and management systems. Our team will assess your current environment and confirm integration requirements as part of the scoping process.
Implementation is scoped to the size and complexity of your operation. It includes a structured assessment phase, phased deployment across sections, workforce training at all levels, and an embedded coaching programme to ensure the system becomes part of your operating rhythm. We stay with you throughout - not just during go-live.
The six-monthly Shaft Audit is a comprehensive expert-led review of your operation's performance, system utilisation, and improvement trajectory. It is designed to ensure the system stays effective and relevant as your operation evolves - and to identify improvement opportunities that might not be visible in the day-to-day operating rhythm.
Most operations begin to see meaningful improvement in production visibility within the first few weeks of go-live. Measurable production performance improvements typically follow within the first quarter, as root-cause work begins to eliminate recurring losses. The scale and speed of improvement depends on your starting point - which is exactly why we start with a thorough assessment.
 
Yes. The MCS Production System and the MCS TSM (Total Section Management) solution share a common platform and data foundation. When you're ready for the additional granularity and broader operational visibility that TSM provides, the transition is straightforward -you build on what's already in place.
 
Pricing is tailored to the scale and complexity of your operation - the number of sections, the level of support required, and the specific modules deployed. We don't apply a one-size-fits-all pricing model. Book a conversation with our team and we will develop a proposal that reflects what your operation actually needs.

EVERYTHING YOU GET

The complete MCS Production System.

MCS Production System - Full Summary

 

Platform Modules

1

CM Monitoring - real-time, accurate production data

2

Control Panel / Admin - centralised production dashboard

3

Downtimes Module - digital capture at source

4

Planning Module - shift-level planning on real data

5

Action Tracker - accountability built into the system

6

Mobile Access - visibility on site, not just in the office

7

6-Monthly Shaft Audit - structured expert performance review

Training, Coaching & Support

1

Underground coaching sessions - section-level continuous improvement

2

GM & Mine Manager coaching - improvement from the top down

3

Root Cause Analysis support - building internal capability

4

Consulting & Recommendations - project plan and improvement roadmap

Strategic Outcomes

1

Data integrity - one version of the truth across your operation

2

Full MOS integration - meetings that drive action, not debate

3

Digital transformation - scalable, integrated, backend-connected

4

37 years of mining expertise - behind every insight

Everything in the MCS Production System is designed to do one thing -give your operation the visibility, structure, and accountability it needs to improve safe production performance consistently, shift after shift.

Ready to take control of your production performance?

Let's have a straightforward conversation about your operation - where you are, what's holding you back, and how the MCS Production System can help you get where you need to go.

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No obligation – Immediate access available – Backed by 37 years of mining expertise