Several methodologies have been developed to manage diesel in open-cast mining due to its high demand and increasing diesel prices. Although the use of diesel-powered equipment in underground mines has increased over the years, effective management thereof has not received the same attention. With the advent of Industry 4.0, data can be utilised more effectively by modern businesses to identify and solve problems in a structured manner. In this study, an underground mine was used as a case study to determine whether a Data, Information, Knowledge, Wisdom (DIKW) method for diesel management could be coupled with the Six Sigma Define, Measure, Analyse, Improve, Control (DMAIC) tool to make more informed decisions and gain new insights to help reduce diesel wastage underground. The new integrated methodology identified diesel spillages and highlighted the biggest contributors to these underground spillages. The Six Sigma DMAIC domain utilised root cause analysis to determine the reason for recent systems failures, followed by the identification of practical solutions to eliminate up to 200 ML (megalitres) of diesel spillage. With this information, the case study mine stands to save over USD 175,000 per annum.
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