Mine-to-Design Reconciliation: Turning Data into Safer, Smarter Mining At the heart of effective open-pit operations lies one critical question: are we mining to design? Using monthly survey data(topography/pit-scan) imported into GEM4D, this reconciliation process compared the pushback design with the as-mined surfaces to evaluate compliance and identify areas requiring corrective action. A color-coded 3D analysis of variances of ±2.5 metres between design and actual pit surfaces is used whereby: • Over-breaks (+2.5 m, blue zones) indicates areas mined beyond design limits. This compromises wall stability and increases the risk of rockfall. • Under-breaks (-2.5 m, red zones) highlight frozen toes and incomplete blasting, often caused by (short drill holes, incorrect burden and spacing, weak bottom charge and inadequate stemming), which also reduce bench catchment effectiveness and safety. By mapping these deviations, the team is able to pinpoint visually where design adherence is lost, assess geotechnical risk, and plan corrective measures such as targeted re-blasting and slope reconditioning. Continuous monitoring through survey updates and movement radar ensures that compromised areas are flagged in the pit hazard plan, reinforcing both safety and design discipline. This exercise demonstrates that mine-to-design reconciliation is not just a compliance check, it’s a powerful feedback loop that improves safety, slope stability, and long-term economic performance. As geological structures and operational realities evolve, frequent design validation keeps open-pit operations aligned, efficient, and resilient.