Mining, oil and gas, refining and process infrastructure

Eliminate turnaround discovery overruns. De-risk FIFO rosters and protect asset margins.

In heavy industry and energy processing, multi-million-dollar losses rarely stem from a single mechanical fault. They emerge from disconnected operations. When discovery work derails a turnaround, FIFO rosters clash with camp caps, or critical trades wait on delayed work permits, plant margins vanish. JanusKS links your enterprise work orders, live scheduling networks, remote workforce logistics and asset health into an active Heavy Industry Knowledge Graph. Resolve scheduling collisions, enforce statutory safety guardrails and execute high-consequence operations with deterministic precision.

Turnaround duration compression
Resequence critical-path work packs within minutes of unpredicted discovery scope to cut idle contractor standby costs.
Fatigue and statutory compliance
Deterministic guardrails check rosters for breaches across complex FIFO and DIDO swings.
Synchronised work-pack readiness
Automatically aligns permits, scaffolding, rigging and parts staging to maximise on-face wrench time.
Air-gapped and remote ready
Full sovereign intelligence deployed directly at remote mine sites, offshore platforms and processing plants, with no dependency on cloud connectivity.

Heavy operations are fractured across siloed systems.

Plant managers, turnaround directors and logistics superintendents work under relentless constraints. When operations rely on isolated spreadsheets, static Gantt schedules and disconnected maintenance modules, small friction points quickly compound into operational stoppages.

Where traditional industrial systems break down

  1. 1

    STO discovery cascades

    Unplanned repairs derail the critical path while trades sit on paid standby.

  2. 2

    FIFO logistics logjams

    Flights, camp beds and shift rotas managed in silos lead to empty seats and crew gaps.

  3. 3

    Cumulative fatigue

    Emergency call-ins compromise safety and trigger stop-work risk.

  4. 4

    Low tool-time friction

    Trades reach the job face only to find missing permits, tags or crane access.

  5. 5

    The production vs maintenance war

    Sweating degraded assets to hit quarterly output risks catastrophic, multi-week emergency outages.

What that looks like on site.

  • The shutdown and turnaround (STO) discovery cascades

    The pain point

    During a multi-week plant overhaul (such as an oil refinery hydrotreater, mining grinding mill reline or smelter rebuild), opening isolated vessels inevitably uncovers unpredicted wear, pipe thinning or refractory failure.

    The operational breakdown

    Traditional scheduling systems can take half a day to re-key and re-level. While planners spend hours manually adjusting dependencies, hundreds of contracted boilermakers, fitters and welders sit idle on paid standby, burning through outage contingencies.

  • FIFO logistics friction and camp allocation logjams

    The pain point

    Remote assets operate as isolated micro-cities dependent on fly-in fly-out (FIFO) and drive-in drive-out (DIDO) shift rotations running intensive swings (such as 2-and-1 or 8-and-6).

    The operational breakdown

    Charter flights are tracked in one system, village accommodation rooms in another, and trade qualifications in standalone spreadsheets. A single commercial airline cancellation cascades into double-booked camp quarters, empty aircraft seats (“deadheads”) and missing statutory trade coverage on site.

  • Compounding workforce fatigue and statutory safety breaches

    The pain point

    Industrial regulators (such as national mining safety inspectorates and offshore safety bodies) enforce strict limits on consecutive shifts, mandatory reset breaks and maximum night-work hours.

    The operational breakdown

    When unexpected absences hit, supervisors scramble to call in available operators without visibility into their trailing 28-day workload. Fatigue compounds, increasing the risk of high-potential safety incidents, vehicle collisions and sudden statutory stop-work notices.

  • Poor work-pack coordination and low tool time

    The pain point

    Across heavy maintenance, actual technician “tool time” (hours spent physically wrenching on assets) frequently hovers between an inefficient 25% and 35%.

    The operational breakdown

    Materials are tracked in enterprise ERPs (SAP PM / Maximo), access permits in safety databases, and mobile cranes in plant equipment logs. Specialist crews arrive at the workface only to discover the scaffolding certification tag has expired, isolation permits are unsigned, or replacement parts remain trapped in the warehouse.

  • The production vs maintenance tug-of-war

    The pain point

    Operations teams are incentivised to maximise daily throughput, while maintenance teams are responsible for equipment reliability and long-term asset health.

    The operational breakdown

    When commodity prices spike, operators delay preventative outages. Without mathematical models to quantify accelerated wear curves, machines run past design margins until critical components fail catastrophically under load, turning an 8-hour service into a multi-week shutdown.

How JanusKS solves industrial friction.

From siloed plant systems to de-risked turnarounds and ready crews.

  1. Ingest

    Integrated ingest

    • SAP PM / Maximo
    • P6
    • Telemetry
    • Camp bookings
    • Safety regimes
  2. Model

    Heavy industry ontology

    • Assets
    • Work packs
    • FIFO swings
    • Permits
    • Spares and tooling
  3. Simulate

    Predict and simulate

    • Critical-path resequencing
    • Camp caps
    • Fatigue thresholds
  4. Outcome

    Operational certainty

    • De-risked turnarounds
    • Fatigue-checked rosters
    • Maximised wrench time

The unified industrial knowledge graph

Map the living relationships across plant equipment, supply lines and site crews.

Move beyond static relational rows and isolated maintenance tickets.

  • Maps physical dependencies between major equipment trains (crushers, autoclaves, distillation columns), auxiliary infrastructure (lube skids, switchgear) and active lock-out/tag-out (LOTO) boundaries.
  • Binds work packs directly to prerequisite site conditions: crane availability zones, gas-testing clearance, environmental permits and emergency response teams.
  • Reveals hidden operational dependencies across plant zones before crews deploy to the field.

High-velocity turnaround (STO) simulation

Absorb scope discovery without missing critical restart milestones.

  • Instant zero-copy branching

    When discovery scope emerges, planners can spin up parallel simulation sandboxes in seconds without duplicating database records or disturbing active site operations.

  • Algorithmic critical-path levelling

    Deterministic constraint solvers evaluate thousands of trade sequences to find the optimal recovery path, factoring in shift changeovers, crane lifting windows and statutory curing times.

  • Controlled merge to live

    Once project leadership approves an updated sequence, JanusKS updates live operational displays and writes milestones back to enterprise scheduling tools.

Dynamic FIFO rostering and fatigue risk governance

Synchronise personnel travel, camp accommodation and safety compliance.

  • Constraint-enforced scheduling

    Solvers validate prospective rosters against fatigue guidelines (hours worked, night-shift spacing, rest breaks) and site-specific safety regulations.

  • Logistics alignment

    Matches planned rosters against camp accommodation caps and flight manifests, eliminating double-bookings and costly chartered deadheads.

  • Automated competency verification

    Verifies mandatory licences (such as high-voltage switching, rigging and confined-space entry) against task requirements before crew mobilisation.

Synchronised work-pack readiness

Ensure trades, tools, permits and materials converge at the job face together.

  • Prerequisite verification

    Flags tasks on the critical path whose prerequisites, such as material clearance, scaffolding inspections or crane access, are not confirmed 24 to 48 hours prior.

  • Closed-loop isolation coordination

    Synchronises permit-to-work issuance with shift handovers, cutting hours spent waiting for manual isolations at shift start.

  • Resource conflict resolution

    Eliminates shared equipment bottlenecks (such as dual demand for a 200-tonne mobile crane) before crews arrive on site.

Bi-temporal asset health and outage planning

End the conflict between production yield and asset integrity.

  • Sensor and telemetry fusion

    Integrates continuous SCADA and IoT streams (vibration, heat, pressure) into the historical asset graph to track true wear progression.

  • Empirical degradation modelling

    Reconstructs historical operating data to identify the point where deferring maintenance increases the statistical likelihood of catastrophic failure.

  • Opportunistic maintenance windows

    Suggests optimal, low-impact inspection opportunities during planned operational slowdowns or downstream bottlenecks.

Comparing approaches: conventional systems vs JanusKS

Operational focus areas compared: traditional industrial management and the JanusKS IDSS platform
Operational focusTraditional industrial managementThe JanusKS IDSS platform
STO scope discoveryPlanners spend 8 to 14 hours manually adjusting Gantt charts while trades wait on paid standby.Spin up zero-copy sandboxes in seconds; automated constraint solvers resequence tasks to protect the restart date.
FIFO and camp logisticsFlights, room allocations and roster rotas managed in separate spreadsheets, causing overbookings and empty seats.Unified spatiotemporal graph synchronises travel manifests, camp bed capacity and site coverage automatically.
Fatigue managementSupervisors manually review punch-clocks after shifts are completed; fatigue risks discovered too late.Continuous constraint validation flags impending fatigue limit breaches before shifts are assigned.
Work-pack stagingSpecialised trades arrive at equipment only to find missing permits, expired scaffolding tags or delayed parts.Dynamic prerequisite tracking helps parts, permits, staging and trades arrive at the workface together.
Maintenance vs productionMaintenance schedules continually pushed back to hit short-term production quotas, risking catastrophic failure.Historical degradation modelling calculates the actual operational risk of delayed maintenance, grounding choices in data.

Industrial security, sovereignty and remote resilience

Heavy industry, mining assets and energy networks represent critical national infrastructure (CNI), subject to demanding security standards and remote operating conditions.

  • Offline and air-gapped deployment

    Deploy the complete graph database, solver engine and private runtimes directly on-premises at remote mine sites, offshore platforms or secure industrial facilities, operating independently of public internet connections.

  • No variable cloud costs

    Simulation runs, continuous anomaly detection and automated schedule evaluations run on dedicated local hardware with no per-token SaaS fees.

  • Industrial cybersecurity alignment

    Built to support corporate compliance with critical infrastructure standards, including IEC 62443, NIST SP 800-82 and the Australian Security of Critical Infrastructure Act (SOCI).

  • Defensible human-in-the-loop governance

    Autonomous solvers surface recommendations, calculate risk trade-offs and highlight schedule conflicts, while final operational approvals, plant restarts and procurement commitments stay firmly with human engineers.

Achieve operational certainty across your critical assets.

Give your plant managers, turnaround superintendents and logistics directors the tools to reduce turnaround delays, support workforce safety and safeguard asset availability.