How we helped
Connecting Berry Llantrisant to people, assets and data
Berry Llantrisant remove silos, paper and manual processes with a connected worker platform to improve hazard closure rate, demonstrate compliance with ease and improve engagement with frontline workers.
Download Full Case StudyThe Problem
Zaptic helps to increase efficiency and communication on the shopfloor
It was clear that Berry Llantrisant needed to digitalise daily manufacturing processes in order to improve hazard closure rate, increase efficiency and communication on the shop floor whilst empowering and enabling operators.
Approach
Why Zaptic?
Zaptic worked with Berry to implement our Connected Worker platform through key initial use cases to make a big impact, quickly.
Andrew Stewart, EHS Manager, highlights: “We believe that Zaptic was the solution for us because of the flexibility within the platform and the support that we got from Zaptic to adapt the workflows and everything that we wanted, and in the way that we wanted, which was fantastic. By using the no-code element, we can actually create our own workflows. And we get support if we’re unsure of how we should configure some things.”
“The use case we rolled out initially was the work request and hazard report. That grew organically into tying together engineering work requests, hazard reporting, safety reports, and quality reports. That grew organically and connected the different departments, and removed that silo mentality.” Rob Jones said.
Berry Llantrisant recognises the importance of digitalisation and strives to eliminate paper from their site.
Rob Jones says: “What digitization brings to the operation is the elimination of paperwork. Paperwork can be open to interpretation, it can be open to scribbles, to being lost. When you look at our operation, we’ve got 38 manufacturing processes. That’s 38 pieces of paper that have been handed back to a shift manager who’s then expected to pick up a small cross or a ‘Not OK’ condition on those pieces of paper, and the likelihood is that they’re going to get missed. With the digital escalation, it’s there immediately, so we can again discuss in the operations meeting and address in a timely manner.”
Why Connected Workers?
Rob Jones believes in empowering and engaging front line workers in daily work instruction in order to improve business results, productivity and efficiency:“The importance of operator engagement is those direct lines of communication, empowering them to raise issues as they see them. Our team now knows that when they escalate an issue that it’s discussed at the next operations meeting, and nothing engages people more than getting those issues resolved.”
Rob continues: “We’re actually getting suggestions from users on the shop floor to say, ‘Maybe Zaptic could be used for this?’ – we’ve got a continuous improvement mentality, really.”
Outcome
The Achievements
Berry Llantrisant experienced quick results by implementing Zaptic and working with our Customer Success team.
Plant Manager, Rob Jones explains: “Within the first six months of introducing Zaptic we saw plant performance uplift, we saw a reduction in downtime, and an improvement in quality.”
He continues: “In terms of performance, we've got a safer plant. Previously, prior to digitalisation, we were raising on average 15 hazard reports per month with a closure rate of 40%. Now we're raising over100 hazard reports per month with a closure rate of over 95%.”
The Future Landscape
Rob looks forward to implementing new use cases and exciting product functionality that Zaptic is rolling out.He explains: “The functionality which we're going to move forward with now is the one point lessons. We think that's a really powerful tool in terms of not only training, but also refresher training. So if somebody is going through a process which is digitised, the ability to link to training documentation, safe systems of work, and these single point lessons, that's really invaluable.
We're embarking on adult apprenticeships to retrain some of our staff, because technical recruitment is very difficult at the moment. And again, to get all of that training literature, literally, at the touch of a button in the process – that's huge.”
