Cleveland Potash

Keeping underground operations safe and compliant at Boulby Mine 

Underground mining starts with one priority: ensuring that only qualified operators use the right equipment and that every vehicle is safe before entering the mine. 

In the UK, strict health and safety regulations make this essential, but in an underground environment with limited visibility and a large dispersed fleet, managing access control and inspection records can quickly become complex and time-consuming. 

This was the challenge facing Cleveland Potash, operator of the Boulby Mine in North Yorkshire. With more than 85 underground vehicles supporting one of Europe’s deepest mines, the team needed a more reliable and efficient way to manage safety and compliance. 

When legacy systems reach their limits 

Cleveland Potash became a Powerfleet customer more than 10 years ago, when their original system had become outdated. 

Operator permissions had to be updated vehicle by vehicle, maintenance data was recorded manually, and paper-based logbooks made reporting and planning inconsistent and inefficient. The previous system had also become aged and obsolete, limiting access-control updates and reporting options. 

A modern approach to underground fleet safety 

Powerfleet introduced a cloud-based access control and digital pre-start checklist solution, initially on eight new Toyota Land Cruiser Troopers before expanding the deployment to 17 additional underground vehicles. 

Today, authorised operators simply identify themselves before starting a vehicle, while digital pre-start inspections are completed directly from the vehicle. 

If a critical defect, such as an oil leak, is reported during the inspection, the vehicle is automatically flagged for workshop attention before it can be returned to service. This gives the diesel workshop a clear digital record of the issue and helps prevent unsafe vehicles from being used before inspection and release. 

Improved visibility and less administration 

The connected platform has also streamlined daily operations. Maintenance hours are automatically sent to the workshop, replacing paper logs and improving planning accuracy. 

The transition was generally positive, with some early access-update delays on vehicles that saw very limited use and needed Wi-Fi connectivity to refresh. Once equipment returned to regular use, those updates became much smoother. 

User permissions can be updated remotely in seconds, with instant access removal when needed and simplified replacement of lost credentials. 

For Cleveland Potash, this means better compliance, improved visibility, and significantly reduced administration, allowing the team to focus on safe and efficient underground operations.