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CheckProof for Cement
Streamline your cement plant maintenance
To run your cement processing plant at maximum availability while ensuring high safety standards, you need effective processes for maintenance and HSEQ. CheckProof’s mobile-first platform is built for the frontline – not just desktop users. Use it as your core CMMS or integrate it with existing systems to streamline routines and documentation, reduce CO2 emissions, and turn operational data into actionable insights.
4 benefits of CheckProofing your cement processing plant
1
Increased asset availability
2
Reduced key-person dependency
3
Improved workplace safety
4
Well-documented quality control
Effective maintenance for the cement industry
Cement manufacturing is complex, energy- and staff-intensive, and takes place in massive processing plants that are kept running at all hours of the day, all year long. The end product is a costly material crucial to a range of other industries (concrete products being one of the main applications). How do you ensure safe and effective operations throughout your entire process?
To achieve this, you need an accurate, traceable, frontline-friendly, and operator-independent maintenance regime. It has to cover all aspects of your operations: from ensuring maximum availability of your feeding system to minimizing the fuel consumption of your yellow fleet.
Cement kiln maintenance: making the most of your planned downtime
Many of your day-to-day maintenance routines can be carried out while your processing plant is running. But maintaining the most critical part – the cement rotary kiln – requires a complete shutdown of production. How do you make the most of this necessary, but costly, downtime?
Getting everything done quickly and correctly requires clear and accessible instructions. You also need an effective way for frontline staff to detect defects and deviations as soon as they spot them, instead of having to wait until they’re sitting at a desk or can get hold of a manager.
Customized checklists and frontline reporting for all your cement plant maintenance
With CheckProof, you can create customized, easy-to-follow maintenance checklists for all stages of the cement production process. Include pictures or videos to further clarify the instructions, or make taking a photo a mandatory part of completing certain tasks.
Every check is automatically logged with time, location, and operator in the app, so you can prove your plant’s routine compliance to customers and third-party auditors. And if an employee notices anything that needs correction, they can quickly submit a deviation report directly from the checklist on their mobile device.
Examples of maintenance checks you can include in your CheckProof platform:
Daily, weekly, and monthly inspections
Start-up and shut-down procedures for fleet and equipment
Step-by-step instructions for kiln maintenance tasks during planned downtime
Cleaning procedures
Condition-based maintenance checks triggered by IoT data
IoT and OEM integrations
Upgrade your preventive maintenance
CheckProof supports usage- and condition-based maintenance through API integrations with well-known OEMs, as well as through our own software for Pigeon devices. This enables you to stream data from connected machines, vehicles, sensors, and asset control systems directly into our platform.
The data input can be used to automatically trigger maintenance tasks based on factors such as operating hours, energy consumption, fuel levels, produced quantity, temperature, or pressure levels. Not only will this make your preventive maintenance more accurate and cost-effective, butou’ll also detect potential risks at an earlier stage, which improves workplace safety.
Reduce CO2 emissions through fleet optimization
By monitoring the fuel consumption and idle time of your mobile fleet through our platform, you can detect and tackle excessive idling. You can even use gamification elements to drive behavioral change in your frontline teams.
Prevent accidents at your processing plant with easy-to-follow safety routines
The health and safety risks associated with cement processing plants and raw material extraction include:
Slipping or falling accidents
Getting hit by moving or falling objects
Getting caught in moving equipment
Explosions or collapses in limestone quarries
Cement dust exposure harming skin and lungs
How do you prevent these hazards from causing workplace accidents in your cement business? Keeping all frontline employees up-to-date on safety procedures, the proper use of personal protective equipment (PPE), and how to correctly carry out on-site inspections can be a challenge.
As with maintenance routines, clear and accessible instructions are key. You also need to establish a strong culture of accountability and maintain it over time as employees come and go. Because if a single person fails to follow safety routines correctly – be it from lack of training or experience, or simply from negligence – the consequences can be fatal.
Use RFID tags for added safety assurance
These days, it’s not uncommon for cement processing to be monitored remotely by operational managers who rarely visit the plant. This makes it all the more crucial to implement safety routines that are completely traceable.
CheckProof lets you create easy-to-follow checklists to ensure safe and correct procedures are being followed, even by staff who are new to the job. For additional safety assurance, you can place RFID tags in crucial places and connect them to corresponding tasks in the CheckProof platform. To mark these tasks as complete, the staff member needs to physically scan the tag with their mobile device. This way, you can be 100% certain that checks are carried out on-site.
Traceable raw material and cement quality control
Whether the raw material for your cement production comes from quarries within your company or from external suppliers, you want to make sure that it meets the agreed specifications on arrival. The same goes for the product you deliver via cement terminals to your customers.
With CheckProof’s mobile app, you can create quality control checklists and let frontline staff include photos and notations in their digital documentation. This way, you’ll have a visual record of the product quality delivered both to and from your processing plant.
Data-driven continuous improvement through structured incident management
By systematically documenting and following up on reported issues related to maintenance and HSEQ, you’ll enable data-driven optimization across your business. Here’s how CheckProof helps you achieve this in a structured and efficient way:
All your data in a single platform
Gather all near-misses, incidents, deviations, non-conformities, quality issues, etc. in a single platform, regardless of who’s reported them: frontline staff, a manager, or a customer.
Examples of issues you can log and follow up on with CheckProof:
Safety incidents such as accidents, injuries, and near-misses
Customer complaints or warranty claims (e.g. out-of-spec quality) via your website forms
Environmental incidents (air quality issues, fuel leakages etc.)
Issues raised by external auditors
Suggested improvements from staff
Customized templates for a structured process
Create customized templates to manage all issues in a way that fit the specific requirements of your company, as well as relevant ISO standards, CE certifications, or environmental regulations. Use dropdown or free text fields to gather information such as what happened and where, the root cause analysis, and the actions taken to resolve the issue and prevent it from happening again.Accountability & traceability – let nothing fall through the cracks
Assign a person responsible for the issue and set a due date for when it needs to be resolved or followed up on. This will ensure that nothing falls through the cracks.Easily share improvements across your organization
Could the solution to a problem be applicable to other areas of the organization? Set the ticket parameters so it can’t be closed until it’s confirmed that all relevant departments have been made aware of the issue and implemented a suitable solution.Turn your data into actionable insights
You can filter issues based on category, export reports as spreadsheets, or integrate the CheckProof platform with your business intelligence systems. This lets you detect patterns and recurring problems that need to be tackled on a larger scale.Discover how to upgrade your cement business with CheckProof
Want to learn more about our mobile-first platform and how it can help you improve safety and save time and money throughout your cement production process? Just contact us or book a 30-minute demo.
