1. The document discusses autonomous mining and outlines some of the challenges and considerations for implementing autonomous systems safely. It describes different approaches to segregating autonomous machines from humans, as well as ensuring proximity detection and collision avoidance systems are designed independently and reliably. 2. Cybersecurity is highlighted as a key challenge, with autonomous systems needing effective cybersecurity management and controls to prevent hacking that could compromise safety. 3. The document concludes with Punch's "Golden Rules" for safe automation, emphasizing people engagement, independent safety systems, continuous optimization, and a risk management approach.

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Presented by
Marcus Punch
RPEng, FSExpert (TÜV Rheinland),
ProfCert(Cybersecurity)
Marcus Punch Pty. Ltd.
Risk and Reliability
Mobile: +61 (0)432168849
Email: marcus@marcuspunch.com
Web: www.marcuspunch.com
28th Electrical Engineering Safety Seminar
7th and 8th November 2018
Safe and Cybersecure
Autonomous Mining

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Overview
Why automation is happening?
Segregated and non-segregated automation.
A ‘reasonable’ safety process.
Challenges.
Cybersecurity.
Punch’s ‘Golden Rules’ of Automation.

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Mining Industry Productivity
“…the general slowdown in productivity growth cannot be attributed to weak investment,
but is likely to be associated with either a slowdown in the pace of adoption of productivity‐
enhancing technological innovations or less rapid improvement in the efficiency with which
capital and labour are employed”.
Patrick D’Arcy and Linus Gustafsson, Australia’s Productivity Performance
and Real Incomes, Reserve Bank Bulletin, June Quarter 2012.

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12 Disruptive Technologies - McKinsey
1. Mobile internet.
2. Automation of knowledge work (non-routine, requiring judgement).
3. The internet of things (web-connected low-cost sensors).
4. Cloud technology.
5. Advanced robotics.
6. Autonomous and near-autonomous vehicles.
7. Next generation genomics.
8. Energy storage devices.
9. 3D printing.
10. Advanced materials.
11. Advanced oil / gas exploration & recovery.
12. Renewable energy.
McKinsey & Company - Disruptive technologies:
Advances that will transform life, business, and the
global economy, May 2013.

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Automation = Productivity Driver
http://www.theaustralian.com.au/business/powering-
australia/graph/work

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Automation ≠ Remote Control
Autonomous: machine that is
intended to accomplish its task/s
within a set of defined operations
without human intervention or direct
control.
Semi-autonomous: a machine which
requires direct control by a human
operator to complete some tasks,
while having a portion of its operating
cycle not under direct human control.

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Segregated Autonomy
People and autonomous machines are kept separate.
An Access Control System (ACS) is placed around
the autonomous production zone.
Access
Barrier
(physical
and/or
electronic)

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Segregated Autonomy
ACS keeps machines in and people
out.
Attempted exit by machine – machine
automatically de-energised before it exits
the autonomous zone.
Attempted entry by person - machines in
the autonomous zone are automatically
de-energised.
The ACS is controlling the risk.
Design ACS to a “sufficient” level of
reliability and independent of the
autonomous control system.

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Non-Segregated Autonomy
No Access
Barrier !
People, manual and autonomous machines mingle in the
autonomous production zone.
A Proximity Detection / Collision Avoidance System
(PD/CAS) protects all entities.

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Non-Segregated Autonomy
PD/CAS keeps machines and
people separated.
Out-of-control machine -
automatically de-energised before it
reaches another person or
machine.
Person too close to an autonomous
machine - machine automatically
de-energised.
The PD/CAS is controlling the
risk.
Design PD/CAS to an “sufficient”
level of reliability and
independent of the autonomous
control system.

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“Less Safe” Autonomy
PD/CAS or ACS not independent of the
autonomous control system.
PD/CAS or ACS not designed to a “sufficient”
level of reliability (eg. SIL).
PD/CAS or ACS not accurate.

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Examples of “Less Safe” Autonomy
GPS used for autonomous guidance and PD/CAS.
- if GPS provides incorrect or inaccurate positioning, this can
affect both the autonomous guidance and the PD/CAS at the
same time.
Autonomous guidance and safety systems use the
same processor / logic.
- if the processor / logic malfunctions, this can affect both the
autonomous guidance and the PD/CAS or ACS at the same
time.
The automation system will need continuous
optimisation – a non-independent safety system will
need to be re-validated whenever the automation
system is changed = lower availability of automation.

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Safety Process
Automation is not risk elimination.
Automation is risk substitution.
- Some old risks (manual operation) are removed.
- Some new risks (autonomous operation) are
introduced.
Care must be taken to control the new risks, so as
to ensure a net safety benefit.
The solution is to use a risk management approach
 identify “reasonably foreseeable” hazards / risks
 analyse risks (cause, likelihood, degree of harm)
 treat (control) risks
 apply the “hierarchy of controls”
satisfy the “reasonably practicable” test
 apply the “functional safety approach”
(ie. for ACS, PD/CAS of “sufficient” reliability).
 communicate & consult / monitor & review .
ISO17757 Earth-moving Machinery and Mining —
Autonomous and Semi-autonomous Machine
System Safety

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Challenges
1. Bring the people with you. Without the people you will not succeed.
2. Do not do this alone – buy the skills and keep them.
3. Is mixed manual / autonomy really necessary?
4. Automation is “buggy”. Be prepared for continuous optimisation.
Independent safety systems are essential.
5. Cybersecurity.

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Cybersecurity

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AS61508.1 Cybersecurity Trap

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Cybersecurity Management System (CSMS)

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Cybersecurity Risk Assessment

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Cybersecurity Security Levels (SL).

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But…..

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Cybersecurity Management = Know Your Enemies.
Hacking as a Service (HaaS), Malware as a Service (MaaS)
– jobs put out to bid.
Free / Cheap Hacking Software and Advice – eg. Backtrack.
SCADA and Control are now regular topics at ‘DEFCON’
and ‘Blackhat’ conferences.
Vendors publish information about vulnerabilities.
Project BASECAMP – www.digitalbond.com

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Cybersecurity and Functional Safety

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Thank-you
Punch’s Golden Rules for Automation
1. Bring the people with you. Without the people you will
not succeed.
2. Do not do this alone – buy the skills and keep them.
3. Identify reasonably foreseeable risks.
4. Use all reasonably practicable safeguards.
5. Make PD/CAS or ACS independent of automation.
6. Make PD/CAS or ACS of sufficient reliability.(eg. SIL)
7. Know your cyber-enemies and their methods.
8. Continuously optimise.
9. Enjoy the journey – this is supposed to be fun!