Poka > Case Studies > Streamlining Issues Management in Manufacturing: A Case Study on Plastico Dise and Poka

Streamlining Issues Management in Manufacturing: A Case Study on Plastico Dise and Poka

Technology Category

Functional Applications - Computerized Maintenance Management Systems (CMMS)
Networks & Connectivity - 5G

Applicable Industries

Packaging

Applicable Functions

Maintenance
Quality Assurance

Use Cases

Inventory Management
Supply Chain Visibility

Services

System Integration
Testing & Certification

About The Customer

Plastico Dise is a leading manufacturer of plastic packaging products for the food and pharmaceutical industries. With production sites in three South American countries and a team of over 250 employees, Dise is well-equipped to provide quality products and services to companies across the region. The company was looking to reduce machine stops on their production lines and improve visibility into why these stops were happening. To achieve this, they implemented Poka, a Connected Worker app, at two of their production sites in 2018.

The Challenge

Plastico Dise, a manufacturer of plastic packaging products, was facing challenges in managing issues on their production lines. The company was struggling with frequent machine stops and lacked visibility into the reasons behind these stops. The issue management and resolution process was cumbersome and inefficient. When operators encountered a problem, they had to contact maintenance through internal telephones and intercoms. The maintenance team would then log the issues, download work orders to a spreadsheet, print and post the paperwork order schedules to a blackboard in the workshop. This manual process was time-consuming and left room for optimization. Additionally, quality, continuous improvement, and IT issues were reported via email, leading to communication difficulties and tracking issues. The company was operating in silos with limited visibility due to the existence of two separate issue reporting systems.

The Solution

To address these challenges, Dise implemented Poka, a Connected Worker app, in 2018 at two of their production sites. Poka revolutionized how maintenance issues were managed at Dise. The app allowed any operator, regardless of their position or seniority, to upload an incident. The operators could choose the issue type, priority level, and location, add a description, and even attach photos and videos for further context. The relevant department or team would be immediately notified via email or push notification. The problem could also be shared on the factory newsfeed to encourage wider support and group problem-solving. Poka also introduced numerical codes for customizable issue types, which helped in prioritizing and categorizing problems for faster resolution. The maintenance team could track open issues on a digital Kanban board or filter them to identify the most critical or persistent problems. Poka was integrated with Dise's CMMS, Hippo, reducing the need for data reentry and saving significant time and labor.

Operational Impact

The implementation of Poka brought about significant operational improvements at Dise. The process of reporting and managing issues became more streamlined and efficient. The app improved communication and visibility of maintenance issues, leading to faster resolution times. The digital Kanban board and priority rankings improved company-wide communication, reducing the need for frequent interdepartmental meetings. The integration of Poka with their CMMS saved significant time and labor, as it reduced the need for data reentry. The more transparent and accessible continuous improvement process resulted in increased employee engagement. Overall, Poka helped Dise achieve labor and time savings, improved issue resolution, and increased employee engagement.

Quantitative Benefit