How this Super Quarry Connected 150 People Across Seven Sites

Challenge
Holcim’s Torr Works Quarry produces around 5.5 million tons of limestone annually and employs approximately 150 people across extraction, production, maintenance, processing, distribution, and drilling and blast.With a footprint this large, consistent reporting and fast visibility into what’s happening on site are critical. Before CheckProof, Torr Works relied on paper-based routines, issues reported over the radio or by email, and limited visibility into whether problems were being picked up and followed through.As Alice Gouldbourne, Higher Apprentice at Torr Works, explains: “Before CheckProof, a lot of issues were reported over the radio or by email, and they might not have been picked up or followed through. Now, everything is captured, assigned, and visible.”The geography of the site made this even harder. Confirming an issue in person could take up to an hour. “The ability to take a photo of a problem and for someone based in the main office to instantly view it on their computer or app is fantastic. That saves so much travel time.”

Solution
Torr Works implemented CheckProof to digitize daily operations across the entire site, moving away from paper checklists, reducing document loss, and making site information available instantly.The site is split into seven demarcated areas, and CheckProof is now used to standardize reporting and connect teams across all of them, from extraction and production to maintenance, drill and blast, and the Health & Safety and Environmental department. Today, Torr Works has 70 active users on the platform.

CheckProof supports a wide range of daily workflows at Torr Works:

Digital inspections and issue follow-up: Issues are captured in the field with photos, automatically assigned to the relevant section manager, and tracked through to resolution. No more chasing, no more lost paperwork.

Health and safety oversight: Daily, weekly and monthly geotechnical inspections are managed through CheckProof, helping the team respond faster and stay proactive. “The biggest benefit has been how quickly we can respond to flagged issues. It’s given us a much clearer picture of what’s happening across the site and helps us keep ahead of issues before they become incidents.”

Maintenance planning with the Planning Tool: After identifying a need for better workload planning during daily team briefs, Torr Works adopted CheckProof’s Planning Tool. The team tailored templates to produce work orders and added risk assessments, work times and digital sign-offs. Plant shutdown windows are built into the schedule, so related tasks can be pulled in when equipment is already offline. “The Planning Tool is probably the most beneficial feature for us at the moment because you can see a live snapshot of what’s going on straight from your computer.”

Environmental data collection: Borehole monitoring data is extracted directly from CheckProof and automatically populates spreadsheets and hydrographs. “It’s taken what used to be a one- to two-day data input task and reduced it to about five minutes.”

Capturing hidden work: Smaller, ad hoc jobs that previously went unrecorded are now logged as work orders, giving managers a full picture of team activity and workload. “Put it on there as a work order, it shows how much they’re doing and helps highlight where the workload really sits.”

Results
Since implementing CheckProof, Torr Works has seen measurable improvements across the business, including less printing, no chasing or lost paperwork, and full data visibility across a complex, multi-area site.

Senior leadership, based at the main office block, can now see exactly what’s happening across the site in real time. “Having that visibility immediately on their computer or phone means they can see exactly what’s going on. It’s built a much better connection between teams.”

Torr Works has also built a detailed operational history around each asset, linking deviations and work orders over time to support better decision-making and CapEx planning. “The history we now have on each asset is invaluable. If a certain asset keeps having issues, that becomes clear right away. We can see hours worked, deviations raised, and work orders linked to that asset, which gives us the data we need for CapEx decisions.”

Adoption has been fast and broad across the site. “I’ve been really proud of how everyone at Torr Works has embraced it. Usually, with a new system, there’s some reluctance, but once I showed them CheckProof for about five minutes, they were all for it.”

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