BHP innovation program unlocks frontline mining solutions
BHP’s inaugural in-house innovator program is set to turn its employees’ practical ideas into solutions that make work safer and more productive, with four innovations from nearly 1,000 submissions selected to be developed into proof-of-concept projects.
One of the winning ideas was an automated burnout arm designed by Olympic Dam casting technician Lucy Williams, who hopes to replace a hazardous manual task with robotics.
Williams works in the South Australian operation’s smelter, where operators burn a hole into the side of an anode furnace using a 3000-degree spark before each cast – a process that exposes workers to significant risks.
Her idea comes from firsthand experience, as she wanted to use robotics instead and eliminate the risk of harm to people.
“I never imagined myself being part of something like this,” Williams said.
“I have been part of every single step of the process and learned so much through the proof-of-concept phase.
“I am extremely excited to see where this goes. I really want to see this robot in the smelter at Olympic Dam, taking away risks, taking operators out of risky environments. I’m so excited to see the change that this may make to our industry.”
BHP’s other winning ideas span robotic maintenance, underwater cleaning technology and automation systems designed to remove workers from high-risk environments.
According to BHP, the technologies also have the potential to be adapted across different sites and commodities.
BHP president of North America and acting president of South America Jess Farrell said the program highlighted the value of frontline knowledge.
“It is the people who are closest to the work who can see the challenges, risks and opportunities to do things differently. What is really powerful is that the people identifying these opportunities are also stepping forward to help solve them,” Farrell said.
“When our teams step forward – not only to identify risks, but to help design solutions, we build a stronger safety culture, an innovation mindset, and a stronger business at the same time.”
The 2026 winners include teams from Olympic Dam, WA Iron Ore, Operations Services and BHP Mitsubishi Alliance (BMA), and Escondida in Chile.