MOTION METRICS™ Expands Payload Monitoring To P&H Rope Shovels, Unlocking Agnostic Load & Haul Optimisation

Payload efficiency is critical in mining, directly impacting productivity, safety, and operating costs. By accurately measuring and controlling material loads, operations can eliminate both underloading and overloading, ensuring every haul cycle is optimised to maximise downstream production. When shovel operators consistently hit their target payload while loading trucks, mines can reduce fuel use and shorten cycle times. By loading trucks to their optimal capacity more quickly, operations can move more material while using less energy and reducing equipment wear and tear. An effective payload monitoring solution can transform haulage performance by turning every load into a precise, data-driven opportunity to boost productivity, lower costs, and extend equipment life.

Weir is proud to announce the global commercial launch of Payload Monitoring for P&H cable (rope) shovels, expanding its proven payload monitoring capabilities across a broader spectrum of loading equipment. With this milestone, Payload Monitoring from Weir’s MOTION METRICS™ brand evolves into a fully agnostic solution, enabling mines to standardise payload measurement and optimisation across mixed fleets and accelerate their path toward more efficient and sustainable operations.

Extending payload visibility to the backbone of production

Cable shovels are the production backbone of many of the world’s largest mining operations, delivering high-volume, continuous loading in large-scale environments. By bringing real-time payload management to these critical assets, MOTION METRICS™ provides operators and site teams with clear, real-time insights into loading performance directly at the point of production, regardless of the equipment being used. This exciting expansion builds on the success of payload monitoring for hydraulic face shovels and backhoes, now extending the same proven performance to larger, high-capacity rope shovel platforms.

Precision measurement where it matters most

Weir’s payload monitoring solution for mining shovels delivers proven accuracy by measuring and tracking material loaded into haul trucks bucket by bucket, achieving payload error of approximately ±5% more than 95% of the time, with field trials demonstrating even tighter performance (as low as ~3.5%), out-performing both truck-based and weigh-bridge accuracy in trial comparisons.

As a more reliable alternative to traditional truck scales, which often introduce variability due to site conditions, maintenance, and calibration challenges, getting load operations done right begins at the shovel.

The result:

• Increased average truck fill and payload consistency
• Faster, more predictable loading cycles
• Lower energy use per tonne moved
• Reduced payload deviation and rework
• More consistent and efficient operator workflows

Driving efficiency through real-time, bucket-by-bucket operator feedback

Beyond measurement, payload monitoring from MOTION METRICS™ transforms data into action, and transparency into opportunity. After all, you can’t manage what you don’t measure.

The system tracks machine movements and measures the timing of every loading cycle, providing continuous visibility into productivity.

Operators receive real-time, in-cab feedback, enabling them to:

• Adjust loading practices instantly
• Hit optimal truck fill targets
• Maintain consistent cycle performance

Supervisors and production teams gain real-time control room visibility, enabling them to:

• Monitor loading performance across all assets
• Identify inefficiencies and performance gaps quickly
• Make data-driven decisions to improve productivity and consistency

This closed feedback loop ensures that optimisation happens both at the point of loading and at the management level, where it drives the greatest operational impact.

Turning data into performance with MetricsManager™ Pro

All MOTION METRICS™ solutions securely manage your data and store it securely on the cloud via MetricsManager™ Pro, our secure digital platform for performance monitoring and reporting.

Through MetricsManager™ Pro, mining teams can:

• Analyse shovel and operator performance metrics
• Identify opportunities to improve cycle efficiency
• Benchmark performance across fleets and sites
• Enable data-driven decision-making across load & haul operations

This centralised, secure cloud-based reporting environment provides full visibility into production performance, supporting continuous improvement across the operation.

A Strategic Partner for Load & Haul Optimization

With P&H support now available, AI-driven Payload Monitoring can be deployed across mixed shovel fleets, delivering a consistent payload standard, fleet-wide optimisation, and seamless reporting through MetricsManager™ Pro.

Supervisors gain clearer visibility into loading performance, while operations teams benefit from actionable insights that drive continuous improvement.

“We’re proud to bring our most advanced payload monitoring technology to P&H shovels,” said Ali Torabi, Senior Engineering Manager, MOTION METRICS™. “This expansion unlocks shovel-based loading intelligence for a much larger share of the global fleet, helping mines move more material with fewer resources, extend equipment life, and make measurable progress toward their productivity and sustainability goals.”

Enabling the Future of Efficient Mining

As MOTION METRICS™ continues to position itself as a strategic productivity partner, the focus remains clear: helping mines maximise tonnes per hour, reduce equipment stress, lower energy consumption, and advance toward more profitable, and ultimately, more sustainable mining practices.

By delivering accurate, real-time payload intelligence across all major loading platforms, MOTION METRICS™ empowers operations to make smarter decisions, improve safety, and drive measurable performance improvements, one load at a time.