The Road That Came With Proof
Customer
FG Gold
Sector
Mining · Gold · Open-Cast
Location
West Africa
Scope
Multi-OEM fleet unification, production reporting, fuel reconciliation
Cognecto modules
Boson + Cortex · Mining solution
Status
Active deployment
The Challenge
Three vendor platforms. Three reports. Three reconciliation problems.
FG Gold's haul fleet had been procured across multiple expansion phases — TATA Advance trucks with their telematics, additional units with 808GPS systems, and custom TCP devices built in-house for tracking specific equipment. Each system had its own portal, its own report format, and its own data export workflow.
Producing a single end-of-shift production report meant exporting data from three platforms, manually reconciling timestamps and asset IDs, and assembling the summary in Excel. The result was production reports that were always one shift out of date and never quite consistent between accounts and operations.
- Three telematics vendor platforms running in parallel — no single dashboard
- Manual data export, reconciliation, and Excel assembly every shift
- Asset IDs, timestamps, and metric names inconsistent across systems
- Fuel consumption attribution variable — losses harder to detect than expected
- Custom TCP devices outside vendor portals — partial data hidden until manual pull
The Cognecto Solution
Boson codecs normalise every device into one schema.
Cognecto's Boson IoT layer ships with codecs for 20+ OEM telematics manufacturers. Within 5 business days of project start, FG Gold's TATA Advance, 808GPS, and custom TCP devices were all reporting into a single normalised data schema. One dashboard, one shift report, one fuel reconciliation workflow across the entire fleet.
Multi-OEM Codec Library
TATA Advance, 808GPS, Mahindra, Fleetedge, and custom TCP/MQTT devices — all supported on day one.
Custom Codec Development
New telematics formats added within 5 business days — no vendor lock-in.
Unified Trip Recording
Every load-haul-dump cycle captured per asset — across every OEM — in one production report.
Fuel Accountability
Issued vs consumed vs GPS-expected reconciled per asset per shift — 99.5% accountability achieved.
Equipment Health Monitoring
Engine, hydraulic, and brake sensors feed predictive maintenance — uptime doubled vs baseline.
African Operating Environment
Platform built to operate with intermittent connectivity, high-temperature edge gateways, and remote deployments.
The Impact
"That is what complete traceability looks like."
Within months of go-live, FG Gold had replaced three vendor portals and the spreadsheet workflow that connected them with one platform serving operations, accounts, and engineering teams from the same data. Equipment uptime doubled. Fuel accountability reached 99.5%. The Excel reconciliation work disappeared.
2×
Equipment uptime vs pre-Cognecto baseline
99.5%
Fuel accountability — losses traceable to specific assets
Multi-OEM
TATA Advance · 808GPS · Custom TCP unified
Zero
Excel reconciliation work between vendor portals
5 days
Custom codec turnaround for new device types
1
Shift report across the entire fleet
"We run a mixed fleet — TATA, 808GPS, and custom TCP devices we built ourselves. Boson talks to all of them. One dashboard, one shift report, no spreadsheets. We needed one platform that could track every truck, every shift, across a mixed fleet from multiple manufacturers. Fuel accountability went to 99.5% and equipment uptime doubled. That is what complete traceability looks like."
FG Gold · Gold Mining Operations · West Africa