Summary

Soprema is a leading manufacturer of waterproofing, insulation and soundproofing products. Safety is the company’s first commitment to its associates and it has a comprehensive Master Safety Action Plan to coordinate and record all actions over the years. But that action plan requires insights from production on safety risks to be effective.

"Every associate shouldn't be far from a click to open the form they need to report a situation"

integration-architecture

Florent explains the beauty in simplicity of the integration created between Poka, Power Automate, OneDrive and Tableau to collect and visualize incident data to enhance safety on the factory floor.

Project "Click" was born to help address this need. Poka is used to scan QR codes on the shop floor to access digital work instructions, forms and updates. Implementing Poka Forms helped Soprema start its journey in managing several small things that add up to create safety, i.e., identifying near-misses and conducting inspections, and driving visibility by collecting incident data. This visualization makes the difference between making the right and wrong decisions. And connecting Poka's Forms to Tableau brought Soprema's safety strategy to life. It was the key to visualize the data to gain actionable insights and engage everyone towards the singular goal.

Poka specialists supported the project by evaluating Soprema's business needs, exploring integration options, building, testing and iterating in a controlled rollout.

As a result of the integration, data flowed from Poka to Tableau where it was aggregated and visualized. The safety dashboards are available for everyone to see. The result is increased awareness of safety risks, and better insight on incidents.

The integration allowed Soprema to answer critical questions to make smarter decisions regarding their operations' safety, including:

  1. Where was my last incident/accident?

  2. Is my action plan focused on the right part of the machine? Are there more "exposed" zones on the machine that we should consider for a new risk assessment?

  3. What kind of injury is most common?

  4. Is my PPE well adapted to the risk in all zones?


The visualization helps supervisors immediately identify vulnerabilities in the plant, prioritize actions based on where they are found, and provide a well-rounded view of the issues across different areas/departments. For instance, when inspecting the fire extinguisher, the mapping shows their status and if any of them didn't get inspected. It also provides the frequency with which some extinguishers are in the red and need to be actioned on or replaced altogether.

As Florent shares, you need to have the right facts to make a good decision. If facts get filtered in informal communication, their decisions become unreliable. On the other hand, collecting data when it happens and is fresh and relevant is valuable in making timely decisions. While timely, accurate data was the focus, empowering the team members by giving them the autonomy to make a change and impact was the ultimate goal. Both these goals were accomplished thanks to Poka's flexibility in integration capabilities with existing safety systems.


results

Reporting on near-misses & injuries now occurs within the hour, rather than a 2-3 day lag thanks to Poka digital forms and QR codes on the shop floor.

In addition to creating a safety culture at Soprema, Poka has helped increase worker productivity by making forms more accessible. Before they were collecting data on paper forms. Forms were hard to find and workers were never sure if they had the right one. The result was, incidents would go unreported. Now, with the quick scan of a QR code, workers access the right form and are able to submit a report often within the hour rather than 2-3 days which was the average delay on paper.