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Epic transformation: securing the mine of the future

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Contributors:
Theresa Sapara,  EY Americas Metals & Mining Center of Excellence Co-Lead
Umang Handa, EY Canada National Cybersecurity Managed Services Leader
Maria Cherkasova, EY Parthenon, Senior Director, Transactions and Corporate Finance
Shagufta Sayani, EY Canada Senior Manager, Mining & Industrial Operations Cybersecurity Lead
Dylan D’Silva, EY Canada Manager, OT Cybersecurity

As mining steps up to meet the future, does your organization have the cybersecurity frameworks in place to deliver advanced operations and meet growing demand?


In brief

  • The convergence of modern technologies is enhancing operational efficiency, resource management and worker safety and promoting environmental responsibility.
  • But tech advancements introduce complex cybersecurity vulnerabilities that traditional cyber solutions may not be prepared to address.
  • It will be important for the sector to rethink its cybersecurity strategies to best protect operational integrity and competitive advantage.

The metals and minerals sector stands at a threshold: one of fundamental transformations driven by the convergence of physical systems, digital intelligence and environmental sustainability considerations. Unprecedented opportunities for operational efficiency, resource optimization, enhanced worker safety and environmental stewardship are being created as the sector integrates advanced robotics with artificial intelligence (AI) and Internet of Things (IoT) devices with comprehensive digital ecosystems.

While such advancements enable metals and minerals companies to optimize resource extraction, maintain productivity levels essential for global economic stability and minimize impact on the world around them, technological evolution is introducing complex cybersecurity challenges that require immediate attention and strategic planning. The interconnected nature of operations is expanding attack surfaces, potentially introducing vulnerabilities that cybersecurity frameworks designed for enterprise information technology environments cannot adequately address.
 

Successful implementation of advanced mining technologies necessitates a fundamental reimagining of cybersecurity approaches, moving beyond conventional models to meet the unique requirements of interconnected operational technologies and environments.
 

A critical contributor to the modern economy, the metals and minerals sector provides essential resources, including rare metals vital for renewable energy technologies, magnifying the consequences of cybersecurity failures and underscoring the need for comprehensive security frameworks that protect both operational continuity and competitive intelligence.

Drone surveying operations in underground mine high-tech equipment industrial environment close-up view safety and precision
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Chapter 1

The mine of the future

A glimpse at the future of mining is already emerging — through autonomous fleets, digital twins, real-time sensing and integrated business intelligence. Change is not focused on a single technology, but on the way exploration, operations, processing and closures are being reimagined as an integrated system. These advances will unlock productivity and agility — and on the flip side, create potential new exposure points that demand cyber-secure attention. The following discusses just a few areas that will require detailed attention as the sector continues its evolution.

Autonomous systems

Future mines will run on self-directed, adaptive systems — from autonomous haulage fleets and drills to processing plants governed by advanced process control. Exploration data, equipment telemetry and AI algorithms feeding into mine plans will allow operations to adjust dynamically1 to ore body, equipment and safety conditions. Robotic drilling and extraction systems will overtake complex tasks or those operating in hazardous environments, guided by machine learning models that continuously improve performance. Centralized command centers will orchestrate fleets across sites, moving toward continuous mining with precision and reduced human exposure.

Intelligent digital ecosystems

Mining operations will be mirrored in digital twins — virtual representations of ore bodies, equipment, plants and logistics — allowing operators to test extraction strategies, recovery processes and closure scenarios virtually, before implementation.2 Sensor-based ore sorting, AI-driven metallurgy and a movement toward “lights-out” processing plants will adapt in real time to changing feed quality and energy availability. Integrated remote operations centers (IROCs) will oversee interconnected systems, providing end-to-end situational awareness, coordination and predictive optimization. These ecosystems will extend beyond the mine site into pit-to-port supply chains, enabling immediate visibility of material flows, greater agility to respond to shifts in supply and demand, and tighter alignment with market dynamics.

Responsible resource management

Continuously looking to provide net benefits for stakeholders and the community, the future mine aims to minimize and account for its footprint as rigorously as its outputs. Advanced sensor networks will monitor water usage, emissions, soil stability and biodiversity — in real time. Waste will be reduced through tailings reprocessing and resource circularity, while hybrid energy systems incorporate renewables into operations. Design-for-closure principles will provide infrastructure that is modular and adaptable, lowering long-term liabilities and reducing community risk.3

Empowered workforce

Mining’s workforce of the future will be augmented, not displaced.4 For instance, rather than operating equipment directly, managers will oversee both autonomous fleets and integrated energy management systems, focusing on coordination and overall performance. Humans will act as planners, analysts and problem solvers, supported by AI copilots, augmented and virtual reality-based training, and globally dispersed but connected talent pools. Autonomous operations and intelligent systems will reduce repetitive manual tasks while increasing safety and decision quality. Combining human expertise with digital intelligence, the workforce will reshape mining operations to be more adaptive, transparent and accountable.

The mine of the future will still dig, haul and process — but with increased agency, incorporating responsible resource use and an empowered workforce. This evolution will not only redefine productivity and safety but also reshape operations. Cyber resilience will be as critical as physical reliability if advances are to deliver lasting value.

A worker in an orange uniform and hard hat observes the dark, lit tunnel in a mining operation. The atmosphere reflects a modern excavation site focused on mineral extraction and safety measures
2

Chapter 2

Cybersecurity frameworks

Securing the mine of the future will require a cybersecurity posture that is both adaptive and as advanced as the technologies it protects. A layered, integrated and resilient cybersecurity framework will be required — one that spans autonomous systems, intelligent digital ecosystems and operational infrastructure.

This framework must address both strategic risks, including geopolitical threats; supply chain vulnerabilities; and environmental, social and governance (ESG) compliance, and tactical threats, such as ransomware, insider threats and sensor spoofing. It must also support continuous operations, real-time decision-making and secure innovation.

Outsourcing threat management

Today’s autonomous haulage, robotic drilling, AI‑assisted planning and remote operation centers have transformed mines into distributed digital systems where safety, productivity and cyber resilience are inseparable. In this context, threat management and managed detection and response (MDR) are no longer back‑office IT functions. They’re frontline operational controls that ingest high‑fidelity telemetry, from fleets, plants, pits and ports; correlate events across IT, operational technology (OT) and AI systems; and act within predetermined decision windows to keep equipment moving and people safe.

Companies are outsourcing these capabilities because operating envelopes have outgrown what site‑level or centrally staffed teams can sustain. Modern mines generate multi‑modal signals obtained through a variety of sources, from autonomous trucks, drills, shovels and collision‑avoidance systems to supervisory control and data acquisition (SCADA) control systems, historians, edge gateways and AI copilots. Viable defenses must normalize data under bandwidth and latency constraints, detect weak signals in noisy time series and preserve forensic integrity — even when links fail.

Service partners bring hardened pipelines for sensor and control system telemetry, robust data signing and buffering strategies for intermittent backhaul, and analytics that understand the physics of mining processes in addition to common attack paths.

The evolving threat landscape

Threat profiles have shifted toward integrity and availability risks, with direct safety and production impacts. Manipulation of ore body models can quietly distort mine plans and value chains. Tampering with dispatch and guidance systems can create unsafe interactions or stall a pit. Compromised environmental and geotechnical sensors can mask tailings or slope stability issues.

Outsourced threat management programs embed mining‑specific intelligence into detections, so signals such as unexpected patterns in blast designs, anomalous edits to shovel firmware baselines or unusual dispatch overrides are treated as high consequence events rather than generic IT anomalies.

Anticipating action

Response plans should be as tailored as detection, with playbooks prioritizing safe states for autonomous fleets, interlocks, and permissive plant controls and actions sequenced in alignment with IROC procedures. Partners that operate MDR for mining environments must coordinate with site leadership, equipment manufacturers and process control teams in advance, so containment actions happen without creating new hazards — especially critical when connectivity is degraded and decisions must be executed under pressure.

Managed services also means having the right talent and coverage needed to meet organizational requirements. Defending converged technologies requires threat hunters comfortable with programmable logic controllers (PLCs), dispatch schemas and controller area network (CAN) bus nuances, as well as cloud security information and event management (SIEM), extended detection and response (XDR), and identity telemetry. Maintaining such bench strength in‑house and around the clock can be expensive. A managed model provides follow‑the‑sun monitoring, accommodates surge capacity during incidents, and anticipates and helps prepare the business for the next wave of cyber threats on the horizon.

Return on investment

Economics and time to value matter. Mines operate on thin margins, under volatile commodity prices, and with strict uptime targets and limited windows for change. Outsourcing converts heavy capital and hiring cycles into a predictable operating service, with defined response outcomes. Systems and technologies can be deployed at pace using prebuilt content for mining platforms and taking previously observed patterns into consideration. And integrations proven out using digital twinning and staging labs can identify potential detections — before they even get to production lines.

Managing expectations

Regulatory exposure and stakeholder expectations also help build the case for outsourcing. With many jurisdictions strengthening requirements around critical infrastructure, incident reporting and operational risk management, investors are relying more and more on credible cyber resilience as part of safety and ESG commitments. Administered threat management and MDR services streamline the collection of supporting evidence and provide the auditability that boards and regulators expect after a major event.

What “good” looks like in practice is clear:

  • Telemetry ingestion that accounts for edge constraints and preserves chain of custody
  • Analytics that model equipment behavior, identify drift in AI decision agents and spot improbable patterns
  • Intelligence tailored to the mining supply chain, including firmware provenance and third‑party maintenance channels
  • Response playbooks written with operators, not for them, with explicit handoffs to IROC, maintenance and original equipment manufacturer (OEM) support
  • Continuous improvement through attack simulations that exercise both cyber and operational teams
  • Governance that makes responsibilities unambiguous across the site, corporate functions, service providers and vendors

EY Cyber Managed Services bring all these elements together for autonomous and digitally enabled mines, from risk detection and operational disruption visibility to sensor networks and response patterns that stabilize first, then investigate — all with reduced response times, fewer false stops, better protection for people and equipment, and the confidence that the mine of the future can operate safely under constant digital pressure.

Cyber resilience and threat readiness

The EY Cyber Resilience competency emphasises readiness across both business and technology domains. For mining, this translates into:

  • Tabletop exercises: simulating OT failures, ransomware attacks on autonomous systems and supply chain disruptions.
  • Resilience metrics: measures that go beyond uptime — gauging recovery time for autonomous fleets, reconfiguration speed for digital twins and failover capacity for IROCs.
  • Integrated risk management: aligning ESG, safety and cybersecurity; for example, making sure biodiversity sensors are protected from tampering that could mask environmental harm.
An engineer in safety gear uses a tablet for inspection while a drone hovers nearby within an industrial setting, demonstrating cutting-edge technology and innovative solutions for modern operations
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Chapter 3

OT security

Given what we’re seeing in practice today, the mine of the future is expected to be an OT environment. Defining an effective OT security environment, the body of policies used to protect this ecosystem, helps guide the effective operationalization of necessary controls.

Keeping it simple

Hierarchically speaking, policies define a set of organization-wide rules or principles used to align and enforce decision-making with strategic objectives, influencing both actions and activities that take place with clearly defined boundaries, such as an OT cybersecurity policy.

Such policies must enable and be reinforced by an OT governance operating model used to establish a structured framework for the ongoing management of a business’s OT cyber practices, including policy maintenance, standard and control baseline model documentation, compliance monitoring, risk management associated with noncompliance, cybersecurity capabilities implementation and operation, and processes and technologies needed to meet standard control requirements.

Checklist manifesto

Standards documents provide specific and detailed controls. Technical by nature, these documents focus on how to best adhere to rules and principles set out by OT cybersecurity standards and baseline model policies, with standard policies defining control requirements for the secure operation of OT systems and baseline models outlining processes to apply control baseline profiles for each mine site and facilitate the selection of control requirements defined in the OT cybersecurity standards.

The effective operation of the mine of the future cannot be conceived without an operational OT cybersecurity program. Our experienced EY teams help enable cybersecurity controls for OT environments aligned with our cybersecurity managed services model, integrating the management of cybersecurity operations for both IT and OT.

Governance, identity and data protection

Securing the mine of the future will demand robust governance and identity frameworks that include:

  • Cyber risk and compliance: embedding mining-specific regulatory frameworks that define critical mineral protection and environmental reporting into governance models.
  • Digital identity: providing secure access for globally dispersed, augmented workforces using federated identity and zero-trust principles.
  • Data protection: protecting sensitive geological data, workforce telemetry and community impact metrics.
Illuminated ining tunnel with tracks and rocks
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Chapter 4

Strategic integration and financial modeling

Strategic integration and financial modeling will be essential for metals and minerals companies determining how best to implement advanced cybersecurity capabilities. As mines evolve into digitally enabled operations, leadership will be forced to make the call on which cybersecurity components to build internally and which would be best to outsource — decisions that will directly influence cost structures, risk exposure, regulatory compliance and the ability to sustain operations under constant digital pressure.

Scenario-based business case modeling provides a disciplined framework with which to evaluate trade-offs, comparing “all in-house” states against a range of hybrid or fully outsourced options. Strategic integration and financial modeling can help bridge recommended technological solutions with real-world business impacts and build a robust business case to quantify both the tangible and intangible benefits of potential advanced mining technologies, such as autonomous fleets, digital twins and cyber-resilient OT environments.

A walk on the upside

But the challenge is not merely about projecting direct cost savings or productivity gains. It’s also about capturing qualitative upsides — improved ESG compliance, enhanced workforce safety and stronger stakeholder confidence — that drive long-term value. A well-structured model can evaluate these factors alongside the status quo, offering a clear view of the incremental value of transformation.

Capturing these benefits requires blending traditional quantitative techniques — cash flow forecasting, scenario analysis and sensitivity testing — with methods that translate qualitative improvements into measurable impacts. For example, maintaining production continuity during a cyber incident can be modeled as avoided revenue loss.

Stronger environmental controls and reduced biodiversity risks are often recovered through lower insurance premiums or financing costs, as well as better workforce protection tied to productivity and retention metrics. Keeping these considerations in mind can deliver a model that reflects the full economic impact, moving beyond operational efficiency to encompass resilience, sustainability and competitive advantage.

Paving the way

Finally, financial modeling supports the evaluation of competing implementation pathways. Different combinations of technologies, sourcing strategies and rollout schedules — such as phased MDR adoption vs. a fully managed threat environment — can be compared on a like-for-like basis, testing how capital intensity, risk profiles and payback periods vary under each option.

Such modeling enables metals and minerals companies to align investment decisions with strategic priorities — whether prioritizing speed to market, long-term cost optimization or risk mitigation — and provides a defensible, data-driven foundation for board-level approval.

The dedicated EY financial modeling and strategy team draws on deep experience in mining and OT security, helping companies translate complex recommendations into actionable strategies that deliver sustainable value.

Bringing together financial, statistical and data science knowledge, we help clients translate data into strategic insight and support business planning and forecasting, capital allocation, scenario and sensitivity analysis, and valuation modeling — capabilities central to assessing costs, risks and benefits of technology transformation in mining operations.

By integrating financial modeling with strategic and operational analytics, we assess the trade-offs between internal development and outsourcing of cyber defense capabilities, simulate the financial and operational impacts of automation and digital twin deployment, and evaluate resilience investments through scenario-based stress testing, creating opportunities to test “what-if” scenarios and visualize the full range of potential outcomes. Designed for clarity and scalability, our project-level, mining-specific models allow for ongoing oversight of performance as new data becomes available and for the assessment of mine performance, tax implications and long-term impairment.

Providing a holistic view connecting technology strategy with measurable business outcomes, our approach empowers metals and minerals companies to make evidence-based investment decisions, optimize resource allocation and resiliently transition toward digitally enabled autonomous operations.


Summary

The mine of the future balances the convergence of technological opportunities with strategic vulnerabilities. As mining operations become more autonomous, intelligent and interconnected, cybersecurity efforts must evolve from being a reactive function to a proactive enabler of safe, sustainable and resilient mining.

Cyber resilience will be as critical to tomorrow’s mines as physical reliability. Integrating EY cybersecurity competencies — from threat management to OT security — can secure the sector’s transformation and deliver lasting value to stakeholders, communities and the global economy.

The views reflected in this article are those of the author and do not necessarily reflect the views of Ernst & Young LLP or other members of the global EY organization.

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