Aggregate Production Excellence
Manage plant safety, product quality, and environmental compliance with digital tools designed for aggregate processing.
The Challenge
Aggregate processing plants combine high-hazard machinery with demanding quality requirements and environmental constraints. Crushers, screens, and conveyors require rigorous guarding and isolation procedures, while BSI specifications demand documented quality testing for every product. Environmental permits add monitoring requirements for dust, noise, and water that stretch small management teams. Paper-based systems can't keep pace with the documentation demands, leading to compliance gaps that surface during HSE visits, customer quality challenges, or environmental permit audits.
How Assistant Manager Solves Aggregate Production Compliance
Each module is designed to address the specific challenges aggregate production businesses face every day.
Digital Checklist
Aggregate plants have high-risk machinery with entanglement, crushing, and entrapment hazards - digital checklists transform inspections from paperwork exercises into genuine safety verification
The Problems
Why This Matters for Aggregate Production
- Machine guarding inspections are ticked off on paper forms without anyone verifying that guards are actually in place and properly secured, especially after maintenance activities
Workers are exposed to unguarded machinery because inspections became a paperwork exercise rather than genuine safety verification
- Pre-start plant checks for crushers, screens, and conveyors are rushed under production pressure, with operators ticking paper forms without properly inspecting equipment condition
Equipment failures occur during operation because defects weren't identified during pre-start checks, leading to injuries, production losses, and costly repairs
- Conveyor and hopper isolation for maintenance relies on paper lockout/tagout records that can't provide real-time visibility of isolation status or prevent premature de-isolation
Workers are injured when equipment starts unexpectedly because isolation wasn't properly applied or was removed before work was complete
The Solution
How Digital Checklist Helps
Digital checklists with photo evidence requirements for guard condition, equipment inspections with defect escalation, and integrated isolation management with real-time status visibility
Every guard inspection includes photo verification, equipment defects are immediately escalated before operation, and isolation status is visible to everyone in real-time
Use Cases:
- • Machine guarding inspection with photo evidence
- • Crusher and screen pre-start safety checks
- • Conveyor inspection and defect reporting
- • Lockout/tagout isolation management
- • Hopper and silo entry permit verification
- • Dust suppression system checks
- • Shift handover inspection documentation
Feature Screenshot
Digital Checklist
Real-World Examples
Example 1: Machine guarding inspections are ticked off on paper forms without anyone verifying that guards are actually in place and properly secured, especially after maintenance activities
Real Scenario
"A worker's arm is caught in an unguarded conveyor nip point. The daily inspection record shows guards were checked that morning, but investigation reveals the guard was removed for maintenance the previous day and never replaced."
Example 2: Pre-start plant checks for crushers, screens, and conveyors are rushed under production pressure, with operators ticking paper forms without properly inspecting equipment condition
Real Scenario
"A screen deck collapses during operation, injuring the operator. Pre-start checks should have identified the damaged deck supports, but the paper form showed no concerns. The operator admits he didn't actually inspect the equipment."
Example 3: Conveyor and hopper isolation for maintenance relies on paper lockout/tagout records that can't provide real-time visibility of isolation status or prevent premature de-isolation
Real Scenario
"A maintenance worker is clearing a blocked hopper when the conveyor starts. The isolation was removed by the shift supervisor who thought work was complete. Paper permits don't provide real-time status visibility."
Staff Training
Aggregate plants have high staff turnover and use complex machinery - systematic training management ensures every worker is genuinely competent rather than just assuming capability
The Problems
Why This Matters for Aggregate Production
- Lockout/tagout competency and plant-specific isolation procedures are covered in induction but never refreshed, with workers forgetting proper procedures or taking shortcuts under production pressure
Incorrect isolations lead to energy releases and injuries, with inability to prove workers were trained and competent in the specific procedures required
- Quality testing competencies for aggregate grading, sample preparation, and BSI test methods are assumed rather than documented, with no systematic verification that testers are competent
Quality test results are unreliable because testers don't have verified competency, undermining product certification and customer confidence
- New workers are put on the plant floor with minimal training because production demands take priority, learning by watching colleagues rather than through structured competency development
Workers operate equipment without understanding safe procedures, leading to incidents and inability to demonstrate due diligence in training provision
The Solution
How Staff Training Helps
Equipment-specific training management with competency assessment, refresher scheduling, quality testing certification tracking, and training records linked to work authorisation
Workers can only operate equipment they're trained and competent for, quality testers have verified BSI method competency, and refresher training is scheduled automatically
Use Cases:
- • Lockout/tagout competency training and assessment
- • Equipment-specific operation training records
- • BSI test method competency verification for quality staff
- • New starter induction with competency progression
- • Annual safety refresher scheduling and tracking
- • Mobile plant operator competency management
- • Conveyor and crusher-specific safety training
- • Dust hazard awareness and respiratory protection training
Feature Screenshot
Staff Training
Real-World Examples
Example 1: Lockout/tagout competency and plant-specific isolation procedures are covered in induction but never refreshed, with workers forgetting proper procedures or taking shortcuts under production pressure
Real Scenario
"A worker is electrocuted while working on a conveyor because he isolated the wrong circuit. Investigation reveals he received LOTO training three years ago but never had a refresher, and was never trained on the specific conveyor's isolation requirements."
Example 2: Quality testing competencies for aggregate grading, sample preparation, and BSI test methods are assumed rather than documented, with no systematic verification that testers are competent
Real Scenario
"A customer challenges product grading after delivery. Your quality tester admits he was never formally trained on the grading procedure - he learned by watching a colleague who has since left."
Example 3: New workers are put on the plant floor with minimal training because production demands take priority, learning by watching colleagues rather than through structured competency development
Real Scenario
"A new operator is injured on his third day. Investigation reveals he received a brief verbal briefing but no structured training or competency assessment. He was expected to learn by watching, but watched someone taking shortcuts."
Safe Supplier
Aggregate plants work with many contractors and customers who access the site - systematic supplier management protects against shared liability and ensures consistent safety standards
The Problems
Why This Matters for Aggregate Production
- Maintenance contractors, equipment suppliers, and specialist service providers work on plant equipment without systematic verification of their competencies and safe working procedures
Contractor activities create risks that plant operators are jointly liable for, and substandard maintenance work causes equipment failures
- Haulage contractors collecting aggregates drive through the plant without proper induction, understanding of traffic routes, or verification of vehicle roadworthiness
Third-party vehicles are involved in incidents, drivers don't understand plant hazards, and inadequate insurance coverage complicates claims
- Raw material suppliers and constituent providers for concrete operations aren't monitored for ongoing quality and certification compliance after initial approval
Supplier quality degrades without detection, affecting product quality and potentially causing certification issues
The Solution
How Safe Supplier Helps
Supplier qualification management with competency verification, site induction tracking, vehicle access control, and ongoing certification monitoring
Every contractor is verified before working on plant, haulage drivers receive and acknowledge site induction, and supplier certifications are monitored with expiry alerts
Use Cases:
- • Maintenance contractor competency verification
- • Hot work permit contractor qualification
- • Haulage driver site induction and acknowledgement
- • Customer collection vehicle access requirements
- • Raw material supplier certification tracking
- • Equipment supplier quality documentation
- • Ongoing supplier performance monitoring
Feature Screenshot
Safe Supplier
Real-World Examples
Example 1: Maintenance contractors, equipment suppliers, and specialist service providers work on plant equipment without systematic verification of their competencies and safe working procedures
Real Scenario
"A maintenance contractor causes a conveyor fire while welding. Investigation reveals they weren't competent for hot work in dusty environments and didn't follow proper fire prevention procedures. The plant operator faces prosecution alongside the contractor."
Example 2: Haulage contractors collecting aggregates drive through the plant without proper induction, understanding of traffic routes, or verification of vehicle roadworthiness
Real Scenario
"A customer collection vehicle reverses over a worker's foot. The driver had never received site induction and wasn't aware of the pedestrian segregation requirements. The plant has no record of any induction."
Example 3: Raw material suppliers and constituent providers for concrete operations aren't monitored for ongoing quality and certification compliance after initial approval
Real Scenario
"Aggregate quality fails customer specification. Investigation traces the problem to a supplier whose quality system certification lapsed six months ago, but your approved supplier list still showed them as compliant."
Action Tracker
Aggregate plants receive requirements from multiple sources - HSE, customers, environmental regulators, internal audits - unified action tracking prevents the gaps between departments where actions get lost
The Problems
Why This Matters for Aggregate Production
- HSE improvement notices, customer quality complaints, and environmental permit actions are tracked in separate systems or spreadsheets, with no unified view of outstanding compliance requirements
Actions fall between responsibilities, deadlines are missed, and the same issues recur because corrective actions aren't systematically completed
- Plant equipment defects identified during inspections are reported verbally or on paper forms that don't trigger systematic repair tracking and verification
Equipment operates with known defects because there's no system to track repairs to completion, leading to failures that inspection had identified in advance
- Quality non-conformance corrective actions from customer complaints and internal audits are assigned but not tracked, with root causes going unaddressed
The same quality problems recur because corrective actions weren't completed, damaging customer relationships and product reputation
The Solution
How Action Tracker Helps
Unified action tracking across safety, quality, and environmental compliance with assignees, due dates, escalation, and verification of completion and effectiveness
Every action from every source is tracked in one system, nothing falls through cracks between departments, and completion is verified before actions are closed
Use Cases:
- • HSE improvement notice compliance tracking
- • Plant defect repair tracking to completion
- • Quality non-conformance corrective action management
- • Customer complaint resolution tracking
- • Environmental permit action compliance
- • Internal audit finding closure
- • Equipment maintenance action scheduling
Feature Screenshot
Action Tracker
Real-World Examples
Example 1: HSE improvement notices, customer quality complaints, and environmental permit actions are tracked in separate systems or spreadsheets, with no unified view of outstanding compliance requirements
Real Scenario
"HSE issued an improvement notice about conveyor guarding. The maintenance team thought the safety team was handling it. The safety team thought maintenance had it covered. Six months later, HSE return to find the action incomplete."
Example 2: Plant equipment defects identified during inspections are reported verbally or on paper forms that don't trigger systematic repair tracking and verification
Real Scenario
"A crusher bearing failure causes a three-day production stoppage. The bearing had been flagged as concerning in three previous inspections, but there was no system to track the replacement action to completion."
Example 3: Quality non-conformance corrective actions from customer complaints and internal audits are assigned but not tracked, with root causes going unaddressed
Real Scenario
"A major customer threatens to cancel their contract after receiving three consecutive non-compliant deliveries. Each time, corrective actions were assigned but never completed because nobody was tracking them."
Document Vault
Aggregate plants manage extensive documentation for product quality, equipment safety, and environmental compliance - systematic document management is essential for certification maintenance and regulatory compliance
The Problems
Why This Matters for Aggregate Production
- BSI product certification documentation, quality test records, and product specifications are scattered across office filing cabinets, laboratory folders, and personal drives
When customers request quality documentation or certification bodies audit, staff waste time searching and may produce outdated or inconsistent versions
- Equipment maintenance records, isolation procedures, and manufacturer documentation are stored in filing cabinets near the equipment where they deteriorate from dust and moisture
Critical safety documentation is unavailable when needed, maintenance history can't be traced, and you can't prove equipment was maintained according to manufacturer requirements
- Environmental permit documents, planning conditions, and monitoring requirements are filed when received but not actively managed, with permit reviews and condition compliance dates forgotten
Permit conditions are breached because renewal dates were missed, or monitoring requirements aren't met because nobody remembered what the permit required
The Solution
How Document Vault Helps
Centralised document management with quality certification tracking, equipment documentation linking, permit condition monitoring, and automatic review and expiry alerts
All documentation is instantly searchable and retrievable, quality certificates are tracked with traceability, and permit conditions trigger automatic reminders before deadlines
Use Cases:
- • BSI product certification and declaration storage
- • Quality test record archive with traceability
- • Product specification version control
- • Equipment maintenance record storage
- • Manufacturer documentation and manual archive
- • Environmental permit and planning condition tracking
- • LOLER examination certificate storage
Feature Screenshot
Document Vault
Real-World Examples
Example 1: BSI product certification documentation, quality test records, and product specifications are scattered across office filing cabinets, laboratory folders, and personal drives
Real Scenario
"A major customer requests quality documentation for a large order. Staff spend hours searching for the relevant test certificates and product specs. Some documents are found in email attachments, some in filing cabinets, some can't be located at all."
Example 2: Equipment maintenance records, isolation procedures, and manufacturer documentation are stored in filing cabinets near the equipment where they deteriorate from dust and moisture
Real Scenario
"Following an equipment failure, HSE ask to see the maintenance history. The records were stored in a filing cabinet next to the crusher. Dust and vibration have destroyed most of the documents."
Example 3: Environmental permit documents, planning conditions, and monitoring requirements are filed when received but not actively managed, with permit reviews and condition compliance dates forgotten
Real Scenario
"Your environmental permit required a specific monitoring programme to be in place by a certain date. The permit was filed and forgotten. When Environment Agency audit, you've been in breach for six months."
Incident Reports
Aggregate plants have specific high-frequency incident types - mobile plant interactions, conveyor entanglement, dust exposure - systematic reporting reveals patterns that prevent serious injuries
The Problems
Why This Matters for Aggregate Production
- Near-misses with mobile plant, conveyor incidents, and equipment failures go unreported because supervisors don't want to create paperwork or slow down production
Warning signs before serious incidents aren't captured, trends can't be identified, and learning opportunities are lost
- Quality incidents and product non-conformances are handled informally by the quality team without being captured in a system that allows trend analysis
Recurring quality issues aren't identified because individual incidents aren't analysed together, and you can't demonstrate systematic quality management to customers or certifiers
- RIDDOR determinations are uncertain because staff don't understand the reporting requirements for the types of incidents that occur in aggregate operations
Reportable incidents go unreported, leading to regulatory enforcement and questions about the integrity of your entire safety management system
The Solution
How Incident Reports Helps
Unified incident reporting for safety and quality with guided RIDDOR determination, trend analysis, root cause investigation support, and action tracking to closure
Every incident is captured quickly and completely, RIDDOR requirements are correctly determined, and trends across safety and quality incidents reveal systemic issues
Use Cases:
- • Mobile plant near-miss and incident reporting
- • Conveyor and crusher incident documentation
- • Quality non-conformance capture and trending
- • RIDDOR determination guidance for aggregate operations
- • Root cause investigation for recurring issues
- • Trend analysis across safety and quality incidents
- • Action tracking from incident to learning implementation
Feature Screenshot
Incident Reports
Real-World Examples
Example 1: Near-misses with mobile plant, conveyor incidents, and equipment failures go unreported because supervisors don't want to create paperwork or slow down production
Real Scenario
"A loader strikes and kills a worker. Investigation reveals at least four near-miss incidents with the same loader in the previous month, none of which were reported or investigated."
Example 2: Quality incidents and product non-conformances are handled informally by the quality team without being captured in a system that allows trend analysis
Real Scenario
"A major customer receives three non-conforming deliveries in a row. When asked to demonstrate your quality improvement process, you can't produce any trend data or analysis because quality issues were handled case-by-case."
Example 3: RIDDOR determinations are uncertain because staff don't understand the reporting requirements for the types of incidents that occur in aggregate operations
Real Scenario
"A worker fractures his hand in a conveyor incident and is off work for two months. Nobody considers whether this is RIDDOR reportable. HSE discover the unreported incident during a routine visit."
Audit Trail
Aggregate plants face scrutiny from HSE for safety, certification bodies for quality, and customers for product integrity - audit trails must satisfy all these stakeholders
The Problems
Why This Matters for Aggregate Production
- Quality test results are recorded on paper laboratory sheets that could be altered or created retrospectively, with no proof of when testing actually occurred
Customers and certifiers question the integrity of quality data, and you can't prove that testing was conducted at the times claimed
- Machine isolation and de-isolation records exist on paper permits that can't prove the sequence of activities or prevent retrospective completion
When incidents occur, you can't prove isolations were properly applied in the correct sequence before work commenced
- Guard inspection records, training completions, and safety checks are documented on paper that could be falsified or backdated
Legitimate compliance evidence is questioned because paper systems can't prove authenticity, undermining your defence even when you did everything correctly
The Solution
How Audit Trail Helps
Complete audit trails for quality testing, isolation activities, and safety checks with tamper-proof timestamps, user identification, and activity sequence verification
Every compliance activity is documented with irrefutable timestamp evidence, quality data integrity is demonstrable, and you can prove exactly what happened and when
Use Cases:
- • Quality testing timestamp verification
- • Sample chain of custody documentation
- • Isolation permit sequence verification
- • Guard inspection completion evidence
- • Training completion timestamp records
- • Document change tracking and version history
- • Evidence retrieval for investigations and audits
Feature Screenshot
Audit Trail
Real-World Examples
Example 1: Quality test results are recorded on paper laboratory sheets that could be altered or created retrospectively, with no proof of when testing actually occurred
Real Scenario
"A customer disputes product quality and requests all testing documentation. Your laboratory sheets show compliant results, but the customer's independent testing shows different values. Without timestamp verification, your data is questioned."
Example 2: Machine isolation and de-isolation records exist on paper permits that can't prove the sequence of activities or prevent retrospective completion
Real Scenario
"A maintenance worker is injured when a conveyor starts. The isolation permit is signed off as complete, but investigation suggests it may have been completed after the incident. Paper permits can't prove timing."
Example 3: Guard inspection records, training completions, and safety checks are documented on paper that could be falsified or backdated
Real Scenario
"Following a guarding incident, HSE ask for inspection records. Your paper records show compliance, but the investigator notes they could have been created any time and questions whether inspections actually occurred as claimed."
Environmental Monitoring
Aggregate plants operate under environmental permits and planning conditions that constrain dust, noise, and water discharge - systematic monitoring protects operating licences and community relationships
The Problems
Why This Matters for Aggregate Production
- Dust monitoring required by environmental permits relies on manual readings that are taken inconsistently and recorded on paper forms that can't be trended or analysed
Dust exceedances aren't identified in real-time, permit breaches occur without warning, and you can't demonstrate systematic monitoring to regulators
- Noise monitoring at site boundaries is required by planning conditions, but readings are taken manually during convenient times rather than at the most impactful periods
Monitoring data doesn't reflect actual noise impact on neighbours, and planning enforcement action follows when complaints reveal the true situation
- Water discharge monitoring and settlement lagoon management is documented on paper with no system to track trends or alert when discharge quality approaches permit limits
Silty or contaminated water is discharged without anyone realising permit limits are being approached or exceeded
The Solution
How Environmental Monitoring Helps
Integrated environmental monitoring with scheduled readings, automatic limit alerts, compliance dashboards, trend analysis, and regulatory reporting support
Permit conditions are monitored systematically with automatic alerts when approaching limits, giving time for corrective action before breaches occur and evidence for regulatory compliance
Use Cases:
- • Dust monitoring with automatic exceedance alerts
- • Boundary noise level monitoring and trending
- • Water discharge quality monitoring schedules
- • Settlement lagoon level and quality tracking
- • Weather condition logging for context
- • Permit limit compliance dashboard
- • Regulatory report generation and submission tracking
Feature Screenshot
Environmental Monitoring
Real-World Examples
Example 1: Dust monitoring required by environmental permits relies on manual readings that are taken inconsistently and recorded on paper forms that can't be trended or analysed
Real Scenario
"Neighbours complain about dust to the Environment Agency. When they request your monitoring records, you discover readings have only been taken sporadically and the data shows multiple unaddressed exceedances."
Example 2: Noise monitoring at site boundaries is required by planning conditions, but readings are taken manually during convenient times rather than at the most impactful periods
Real Scenario
"Your noise readings show compliance because they're taken during quiet periods. Neighbours' own monitoring during peak production shows exceedances. Planning enforcement threatens your operating consent."
Example 3: Water discharge monitoring and settlement lagoon management is documented on paper with no system to track trends or alert when discharge quality approaches permit limits
Real Scenario
"Heavy rain causes settlement lagoons to overflow, discharging silty water. Environment Agency testing shows permit breaches. Your monitoring records are too sparse to show you were managing the situation."
Results Aggregate Production Businesses Achieve
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Build on Solid Compliance
Join aggregate producers using Assistant Manager to maintain safety and quality excellence.