Panel conversation at CheckProof’s Industry Summit: Digital Maintenance – Learnings from the field

At CheckProof’s recent Industry Summit, three experts – Tim Copping (Breedon Group), Matt Dare (Power X Equipment), and Tom O’Boyle (Heidelberg Materials) – shared their experiences implementing digital maintenance strategies in a panel discussion on “Digital Maintenance – Lessons from the Field.”

Their conversation revealed how modern engineering mindsets, combined with data-driven systems, are improving safety, reliability, and business profitability across heavy industry.

From Reactive to Predictive Maintenance

Q: Have you leveraged real-time data for predictive maintenance?

A major theme quickly emerged: the shift from reactive to proactive maintenance.

Power X Equipment began implementing this approach this year, introducing machine hour tracking similar to automotive models. Automated alerts now trigger job cards and assign engineers via mobile devices.

"Before this, we spent most of our time reacting," said Matt Dare. "Everything was on spreadsheets or informal messages. Now we can plan ahead."

The system also ensures compliance - a critical factor - while reducing operational risk.

Heidelberg Materials shared a similar challenge. Relying on disparate systems had been “an absolute nightmare,” according to Tom O’Boyle. Once data was consolidated into a single platform, planning became more structured and dynamic.

Q: Can you share an example where insights from CheckProof helped prevent downtime or operational risk?

O’Boyle described a recurring issue in a tertiary section, where standard deviation templates helped pinpoint failing components. Tri-axial vibration monitors flagged deviations three to six weeks before audible signs appeared, allowing preventive action. This reduced downtime, minimized risks, and in some cases allowed teams to replace only a bearing instead of an entire gearbox.

Meanwhile, Breedon Group integrates OEM alerts and data to anticipate component failures, and Power X applies similar strategies for wear items like liners and blow bars. Planning ahead for high-cost components - such as a conveyor belt, where downtime can cost £5,000/day - keeps operations running smoothly and avoids emergency expenses.

Integrating Data for Holistic Insight and Efficiency

Q: What value does integrating maintenance data with other operational systems bring?

Breedon Group combines Power BI dashboards with OEM data and CheckProof records to track maintenance check completion, identifying both areas of excellence and underperformance. Their long-term aim: integrate all maintenance, plant, and telematics data into a single system - potentially creating a national operations room to spot and solve issues before failures occur.

For Power X, integration also provides commercial value. Telematics data from OEMs like Terex Power Screen feeds into CheckProof, allowing the company to document downtime, secure supplier credits, and resolve disputes using timestamped GPS-verified production forms.

Q: What new cost savings and efficiencies has CheckProof introduced that weren’t there before?

Digital platforms often reveal hidden benefits. Tom O’Boyle tracks work time across internal staff and contractors, identifying skill gaps and guiding targeted training. By bringing more tasks in-house, the team reduces reliance on external contractors. Tracking “mean time to repair” (MTTR) also allows experienced staff to mentor others, boosting overall efficiency and safety.

The Future: AI, IoT, and User Adoption

Q: Looking ahead, how do you see IoT, AI, or advanced analytics shaping your maintenance strategy over the next three to five years?

Tim Copping expects increased use of sensors combined with generative AI, allowing engineers to “almost speak to your dashboards” and extract actionable insights without sifting through spreadsheets. Breedon is already experimenting with generative AI to analyze maintenance data.

Matt Dare highlighted AI’s potential to automate parts identification across changing machine models, reducing errors caused by ordering obsolete components.

Q: What has been the biggest challenge in getting user adoption, especially among an aging workforce?

The panel agreed that persistence and leadership buy-in are crucial. Regularly asking operators “Have you raised a deviation?” reinforces the process and eventually embeds it into daily routines. Leadership engagement ensures the system becomes part of company culture, with attention to key metrics like availability, compliance, and ROI.

Breedon Group has consolidated multiple inspections - maintenance, HSEQ, and more - into a single platform, creating a “one-stop shop” for site personnel. Panelists also emphasized the importance of standardized data (fault codes, asset names) and engaging staff for feedback, ensuring buy-in while maintaining safety.

Key Takeaways

• Predictive maintenance reduces downtime, mitigates risk, and protects business outcomes.
• Integrating maintenance, operational, and telematics data unlocks new insights and efficiency gains.
• AI and IoT are set to transform maintenance, but adoption depends on people as much as technology.
• Clear standards, leadership involvement, and frontline engagement are essential for long-term success.

Digital maintenance isn’t just a technology upgrade, as these industry leaders and panelists show – it’s an ecosystem of benefits, including structured data, proactive planning, and collaboration that can deliver safer, more reliable, and profitable operations.

Watch the highlights from the panel discussion in our reel.