Colorpak and its sub-business BrandPack design, print and manufacture cardboard cartons and packaging for a range of consumer products, from chocolate through to paracetamol tablets.
Colorpak was pleased with its product range but was looking for a better way to manage risk and deal with incidents as they arose.
It was implementing a new ERP system and also wanted to improve customer service and increase staff engagement.
The team heard about Promapp, business process management software that helps organisations build, improve and share their process knowledge from a central online repository.
Before implementing Promapp, Colorpak had no single way to manage risk or log incidents. Promapp enabled it to manage ISO, and health and safety accreditation and incidents on one platform.
Higher employee engagement along with faster, more efficient handling of issues through Promapp’s incident management module means most problems are now picked up and resolved before they reach the client. Before Promapp, the majority of incidents were generated by customer complaints – now they are often picked up in the system by employees, which means they can be resolved before they impact customer service.
“For me the incident management module really tied it all together," Colorpak general manager Garth Pickett said.
"It brings your health and safety incidents and your quality incidents together onto a platform which then uses workflow to manage resolution of those incidents.”
Knowledge is power
Staff engagement was one of Colorpak’s goals when it chose to work with Promapp. Pickett wanted staff at every level to take responsibility for mapping and improving their work processes.
To achieve this, all staff who had a login or access to a work terminal were trained on Promapp so they could start accessing process maps straight away.
After that, process leaders emerged and started working to improve their own processes. Because Promapp allows for collaboration and sharing work, it provided a forum for constructive debate and decision-making around who was responsible for each process.
“Promapp is a natural vehicle for creating ‘one source of the truth’ and one reference point for process info," Pickett said.
"It made it easy to clarify hand-offs – where responsibilities and authorities started and ended. It generated a lot of positive energy and constructive debate which allowed us to get to best practice early and then to maintain it.”
Once the Colorpak team had most of their processes mapped to reflect their view of best practice, they overlayed the risk management module onto the processes they’d mapped. This enabled them to integrate GMP & HACCP – a critical requirement for their business.
Finally, they implemented the incident management module to manage non-conformance and health and safety incidents.
Pickett said this was key to Colorpak’s ability to drive continuous improvement through their processes.
Peak performance
As risk and incidents are now managed effectively in one place, mistakes are less likely for Colorpak.
When they do occur, they’re picked up and resolved quickly, so they don’t impact clients.
Prior to Promapp, delivery was measured by accuracy per day – on a good day they would get to 90 to 95 per cent. Now, they can go weeks without a single error.
“We now measure delivery performance not in percentage DIFOT, but in weeks of 100 per cent Delivery In Full On Time,” Pickett said.
Change for the better
After three years of using Promapp, Colorpak has changed the way it works. Staff are more engaged, delivery levels have improved, and mistakes are caught before they reach the customer.
About Promapp
Promapp is a type of business process management software helps organisations build, improve and share their process knowledge from a central online repository.
The cloud-based software drives business process improvement by simplifying process mapping, so that teams can own and improve their own processes.
Promapp has more than 300 customers in New Zealand, Australia and the US, including Coca-Cola Amatil, McDonalds and Fisher & Paykel.
