Case Study: Tetra Pak achieves an 87.4% reduction in knowledge gaps with Poka

Eradicating Man & Method Losses in Production

Tetra Pak, a global leader in food packaging with a mature TPM/Continuous Improvement practice, faced growing “man and method” losses once equipment was optimized and needed a way to link worker skills to production loss. Disconnected local systems, paper SOPs and skills tracked in Excel made it hard to identify skill gaps or deliver timely shopfloor knowledge. Tetra Pak selected Poka in 2019 as the Operations Knowledge Management solution to enable a worker‑centric, digital approach to training and SOP delivery.

Poka was rolled out using a three‑phase OKM approach and is live at 18 of 56 sites (about 2 sites/month), giving workers QR access to over 20,000 instructions and troubleshooting resources and using Skills, Forms, SOPs, videos and Viewing Reports to close gaps. The Poka implementation reduced the lamination test knowledge gap from 2,147 to 271 — an 87.4% reduction (target 85%) — and now complements Tetra Pak’s LMS and maintenance systems while measurably eradicating critical skill losses.

Tetra Pak

Johan Lantz

Global World Class Manufacturing Integration Manager