In 2015, a Danone plant in Boucherville, Canada, began using Poka to improve knowledge sharing and communication in production. Today, Poka is Danone’s standard for factory floor performance support across 30 sites in all divisions. One of those sites is a 727-employee Dairy plant in Bierún, Poland.
Sustainability is a core Danone value exemplified by the Bierún plant. The company’s “One Planet. One Earth” program aims to reduce water usage, CO2 consumption and waste. To that end, the site is working towards a paperless factory with the help of Poka digital forms.
It takes 10 liters of water to produce one A4 sheet of paper. Additionally, paper accounts for around 26% of landfill waste—a number that is expected to double by 2060.
With Poka’s help, Danone Bierún won a Paperless Factory Award and Certification in 2021
Danone has already moved nearly 300 processes off paper across 11 factories with Poka forms. In Bierún alone, this will save approximately 40K printed sheets of paper per year and avoid using valuable shop floor space for storing paper forms. Shift leader reports, for example, previously generated over 100 printed pages each month—they are now entirely digital.
Poka is proud to have contributed to Danone Bierún winning the Paperless Factory Award and Certification this year.
As if working hard to save the environment wasn’t enough, Danone has seen improvements in daily routines and productivity since the Poka Forms adoption. For example, it was a struggle to engage employees in defect reporting using paper. Since moving to digital forms, the company has doubled its defect handling system engagement.
Here’s a view of the Poka Journey at Bieruń, with over 400 forms completed and over 100 contributors on the platform
Magda shares, “We can now go to the iPad and fill Poka forms during Gemba walks and move from whiteboard signatures to digital signatures for CIL checklists. We’ve saved the equivalent of 141 hours per year by going paperless!” Moving to Poka not only provides more space on the shop floor but also sends an instant notification to supervisors on completed processes entered in Forms.
Danone, Digital Manufacturing Manager
What’s more, the problem-solving forms even directly link to calls-for-help in the Poka app to provide context on troubleshooting issues. Users can easily communicate information such as descriptions, analysis, solutions and next steps right where it’s needed. Magda shared that they can also use Poka Forms to quickly add all safety audit information directly to the platform without manually inputting information from paper to computers. Danone expects to further leverage Poka forms with the addition of new capabilities like conditional logic and scheduling in the coming months. The ultimate goal is to ease the daily routines on the shop floor, ensure procedures are followed consistently and gain greater visibility into production.