From frontline idea to breakthrough innovation at BHP

Key points: 

• BHP’s Breakthrough Open House is helping frontline employees turn practical ideas into tested solutions that can make work safer, smarter and more productive.
• The inaugural in-house innovator program received nearly 1,000 submissions from across BHP, with four winning teams selected to develop proof-of-concept projects.
• Innovations include robotic maintenance, underwater cleaning and automated furnace casting technology.

Lucy Williams works at the heart of our Olympic Dam smelter in South Australia. 

As a casting technician, Lucy helps operate and monitor the casting process that turns molten copper into copper anodes. It is a high-risk task that involves an operator burning a hole into the side of the furnace using a 3000-degree spark, before every single cast. 

It is complex, manual, high-temperature work where precision matters, and safety is critical.

Lucy’s idea for an automated burnout arm for anode furnace casting comes from firsthand experience – she wanted to use robotics instead, eliminating the risk of harm to people. 

Lucy’s idea is one of four winning projects selected through BHP’s Breakthrough Open House, an in-house initiative established to help frontline teams turn practical ideas into action by connecting them with funding, technical expertise and support.

“I never imagined myself being part of something like this! I have been part of every single step of the process and learned so much through the proof-of-concept phase,” said Lucy. 

“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.”

The program builds on BHP’s Open House approach, which connects external innovators with operational challenges. The Breakthrough Open House applies that same thinking internally, creating a pathway for employees and embedded contractors to share ideas that can improve safety, productivity and performance.

From nearly 1,000 submissions, four were chosen to progress through a proof-of-concept process. 

The innovations include robotic maintenance, underwater cleaning technology and automation designed to remove people from high-risk work. Importantly, they can scale and be adapted more broadly, helping teams tackle similar challenges across different sites, commodities and operating environments.

Through the program, teams even began collaborating and developing their innovations together. For example, the WA Iron Ore team saw a powerful opportunity to adapt a custom-designed lancing rod from BHP’s copper smelter operations to their mining and mobile equipment workshop.

Jess Farrell, President North America and Acting President South America, said the program demonstrates the power of combining frontline expertise with the right support and resources.

“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.

“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.”

Innovation thrives within the BHP Operating System, where people are empowered to solve problems at the source and continuously improve safety and how we work.

Chief Technical Officer Johan van Jaarsveld explained the program shows that innovation is not separate from operations, but part of how BHP improves.

“Breakthrough Open House shows the power of our people identifying risks and helping to design solutions. These practical solutions are grounded in real work and driven by the people who understand them best, strengthening our safety culture and continuously improving how we operate.”

Chief People Officer Jad Vodopija reinforced that it reflects the culture BHP is building.

“Nearly a thousand ideas came forward from people closest to the work, showing a willingness to seek better ways, make a difference and do what is right. Our finalists progressed their ideas alongside their day-to-day roles because they believe in the impact they can create. That is exactly what we want to encourage – innovation as part of how we improve the work every day.”

While each participant presented a single idea, the value comes when solutions can be scaled across multiple assets, recognising shared frontline challenges.

“We are incredibly proud to have so many talented people who care deeply about improving the way we work,” finished Jess. 

“From workshops, mining operations and processing plants around the world, they are shaping a safer and more productive future for our entire industry.”

Congratulations to our Breakthrough Open House 2026 winners:

• Brendan Kitchiner and Ellen Thomas, Operations Services and BMA, Australia 
• Gino Villalobos, Escondida, Chile
• Lucy Williams, Copper South Australia, Australia 
• Dan Carroll and Shane Cordingley, WA Iron Ore, Australia
• Chris Pope and Mitch Elliot, WA Iron Ore, Australia

About BHP Invent

Breakthrough Open House is an initiative of BHP Invent, BHP’s global innovation team connecting new ideas and technologies with opportunities across our operations.

More information on BHP Invent can be found here: BHP Invent | BHP