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Poka > Case Studies > Digital Transformation and Scaling of Operator-Centric Culture at Barry Callebaut
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Digital Transformation and Scaling of Operator-Centric Culture at Barry Callebaut

Technology Category
  • Cybersecurity & Privacy - Intrusion Detection
  • Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
  • Education
Applicable Functions
  • Maintenance
Use Cases
  • Additive Manufacturing
  • Manufacturing Process Simulation
Services
  • System Integration
  • Training
The Challenge
Barry Callebaut, a global leader in high-quality chocolate and cocoa products, faced challenges in maintaining open communication and problem-solving across its 64 manufacturing plants worldwide. The company relied heavily on Gemba walks and team boards for daily operations, which allowed management and functional experts to support operators and address issues. However, tracking issues and reaching the right individual for resolution was a complex task. Additionally, the company needed to ensure that solutions found at one plant were shared across all sites for organization-wide learning. Another challenge was the need for real-time information access for effective decision-making. The company started recording team meetings and sharing them on the factory feed for improved visibility during the COVID-19 pandemic, but needed a more robust solution for data-driven decision-making.
About The Customer
Barry Callebaut is a Zurich-based global leader in high-quality chocolate and cocoa products. With a heritage of over 175 years in the chocolate industry, the company employs over 12,500 people across 64 manufacturing plants worldwide. Barry Callebaut is committed to maintaining an operator-centric culture, where frontline employees are empowered and given the autonomy to execute their jobs and be part of the solution. The company values open communication and problem-solving and is dedicated to continuous improvement and learning at the organizational level.
The Solution
Barry Callebaut implemented Poka, a connected worker platform, to streamline communication and problem-solving. Poka made it easier to track issues and reach the right individual for resolution. It also facilitated the sharing of solutions across different sites, promoting learning at the organizational level. The company also integrated Poka with their manufacturing execution system (MES) to access real-time sensor data from the lines, enabling quick and data-backed decisions. Poka also fostered an operator-centric culture by empowering frontline employees and giving them the autonomy to execute their jobs and be part of the solution. The platform centralized all communications and knowledge, increasing visibility and fostering collaboration. It also facilitated faster issue resolution and consistent updating and documentation of standards, creating a continuous improvement cycle. The company also invested in training and follow-up to ensure the successful adoption of Poka.
Operational Impact
  • The implementation of Poka has significantly transformed Barry Callebaut's operations. It has fostered a real operator-centric culture, empowering frontline employees and giving them the autonomy to execute their jobs and be part of the solution. The platform has centralized all communications and knowledge, increasing visibility and fostering collaboration both vertically and horizontally. This has led to faster issue resolution and consistent updating and documentation of standards, creating a continuous improvement cycle. The integration of Poka with the company's manufacturing execution system (MES) has also enabled access to real-time sensor data from the lines, facilitating quick and data-backed decisions. Overall, the adoption of Poka has made employees' lives simpler and more rewarding, contributing to the creation of an operator-centric culture.

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