Mannok has introduced new screens across the facility displaying real time production information through dashboards for every line, providing every member of the team with information on manufacturing levels and increasing production efficiency to help meet customer demand across Ireland and the UK.

The five new production dashboard screens, which have been carefully installed in the most beneficial areas of the facility, have significantly improved operational efficiency and reduced downtime. With everyone in the facility having access to live information for the various stages of production, the team is fully engaged in their shift’s production levels which enables quicker responses to resolve any potential issues.   

While working directly with BMS Vision, the system which monitors production at various stages on each line, Packaging’s Management Team and the company’s Business Change Team have transferred the production line information into easy to understand, colour-controlled dashboards displayed on screens throughout the plant.

Commenting on the new Production Dashboard Screens, Denzil Kerr, Packaging’s Production Manager, said,

“While we were adopting Lean Manufacturing principles across our facility to maximise our productivity, it was apparent that displaying live production data throughout a manufacturing area has significant benefits to operational efficiency.

Prior to our manufacture information being displayed digitally through dashboard screens, BMS Vision provided our management team with end of day reports, so we would have been focusing on production from the previous day, whereas now everyone across the business is continually improving present manufacturing levels to meet the displayed KPIs.” 

The new digital production dashboard screens are one of a range of Lean initiatives introduced throughout the Packaging facility as part of the company’s Operational Excellence Programme, Leading Excellence.

Leading Excellence is a multi-facet programme, which provides a transferable framework based on four core pillars of Lean, Sustainability, Skills and Development and Continuous Improvement. It focuses on embedding these elements in everyday work throughout the organisation to support the long-term sustainability of the business while ensuring optimum efficiency and added value for customers. 

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Mannok has developed a new digital solution which has made the picking and packing process of customer orders in its consumer packaging facilities paperless. The new app for picking and packing customer orders has removed around 30,000 pieces of paper per year from the process and is saving up to 400 hours of non-value-add activity. READ MORE

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Mannok has launched a new Leading Excellence Programme, which will be implemented in every area across the business, to achieve and sustain the highest operational standards through the core principles of teamwork, problem-solving, innovation and leadership. READ MORE

Mannok has developed a new digital solution which has made the picking and packing process of customer orders in its consumer packaging facilities paperless. The new app for picking and packing customer orders has removed around 30,000 pieces of paper per year from the process and is saving up to 400 hours of non-value-add activity.

The new Paperless Picking App, which was developed in-house by Mannok’s Business Change team in collaboration with order picking and administration personnel, has streamlined the process of pallet loading to fulfil customer orders, ensuring greater efficiency.

The digital solution provides access to real time order status and live communication between teams in the warehouse and the despatch office, with the app installed on handheld devices and forklifts for any time access. Eliminating the need for frequent office visits for paperwork and administration and ensuring a seamless flow of information, has saved 400-man hours annually and helped increase productivity in order fulfilment.

Commenting on the success of this digital initiative for the Mannok packaging plant, General Manager, Mark McKenna, said,

“It was our ambition to improve the process within our warehouse function through the framework of our Leading Excellence Programme, which focuses on adopting Lean and Continuous Improvement principles to not only improve operational efficiency, but also aims to ensure we operate in a more sustainable way.

The Programme commits to examining every process, every task and every role and challenging ourselves to improve it through the core principles of teamwork, problem solving, innovation and leadership.

The development of the Paperless Picking App is a prime example of how this framework can help us achieve operational excellence and reduce our impact on the environment.

It has also been very rewarding to have one of our Ulster University placement students, Jodi Curtis, recognised for her work on the app’s development in the University’s Innovation in Placement awards.

We now look forward to analysing and enhancing more of our processes to ensure our whole business is operating as efficiently and sustainably as possible.”   

Mannok’s Leading Excellence Programme provides a transferable framework based on four core pillars of Lean, Sustainability, Skills and Development and Continuous Improvement. The multi-faceted programme focuses on embedding these elements in everyday work throughout the organisation to support the long-term sustainability of the business whilst ensuring optimum efficiency and added value for customers.  

Mannok has launched a new Leading Excellence Programme, which will be implemented in every area across the business, to achieve and sustain the highest operational standards through the core principles of teamwork, problem-solving, innovation and leadership.

The programme provides a transferable framework based on four core pillars of Lean, Sustainability, Skills and Development and Continuous Improvement and will help the company achieve best in class standards across its entire operations.

By engaging all employees at every level in the business, the Programme will ensure each individual gains the necessary skills and knowledge to continually improve every process, making operations more efficient and sustainable and building a culture of continuous improvement.  

Explaining how the Programme will benefit the company and its people, Operations Director, Kevin Lunney, said,

“Continuous improvement and getting the best out of all our resources is key to the business success. Our industry is going through unprecedented change. We have a focus on lifetime sustainability of our products and a continuous need to innovate. We know our people have the ability to meet these challenges and we want to put in place the framework to support that.

We will equip all our people with the skills required and provide the most appropriate training and support to achieve operational excellence and achieve their career goals.

We will look at every task, every role, every process and rethink it, challenging ourselves to improve it, to make it more efficient, more sustainable, and safer wherever possible.

As we strive to achieve operational excellence the net result will be a highly efficient business with greater productivity and a multi-skilled, motivated workforce and significant benefits for our customers and people as well.”

Lean  

Mannok is focused on creating a work environment which maximises productivity whilst minimising waste and has already seen how the adoption of Lean principles can result in performance improvements and waste reduction. 

Through the rollout of the new Programme, the company will build on these successes by honing and progressing Lean activities in these areas, and go on to establish Lean principles in every area of the business.

By removing inefficiencies and streamlining services right across the company, aided by cutting edge technology and data analysis, the company will reduce costs and environmental impact, and ensure it consistently delivers the highest quality products and services to its customers. It will also create a positive, more engaging work environment for all employees.   

Sustainability  

Lean is designed to reduce waste, much of which will help improve how Mannok operates from an environmental perspective, such as reducing material waste, energy and water usage.  

As the company integrates Lean and Continuous Improvement throughout the organization, it is also committed to embedding sustainability considerations at every point. Every time a task, process or role is assessed for improvement, sustainability considerations will form an important part of the review to ensure improvements will also reduce the environmental impact where possible.  

Skills & Development  

Mannok aims to provide a clear developmental pathway for each employee under the Programme, to enable them to become confident and competent within their role and achieve their career goals.

The company already has a strong foundation in place, having established its award-winning Skills Development Programme in four of its core manufacturing facilities and introduced, a structured Lean training programme. The Leading Excellence Programme will interlink and extend the existing training initiatives to enable all employees to become multi-skilled and provide structured development pathways with all the necessary support to help achieve career progression.

Continuous Improvement  

To achieve true operational excellence, it is not enough to make improvements once. It must be an ongoing process, where the business continually strives to improve how it operates and seeks to do everything better.  

Through the new programme, Mannok will build a culture of continuous improvement whereby all employees at all levels are engaged in actively ensuring the improvements are sustained and constant review is an integral part of daily working life to find ways to further improve processes through continual review and incremental change.   

Conor Baxter, Operational Excellence Manager at Mannok, who has developed and is leading the Programme, commented,  

“We have built a comprehensive framework which will challenge us to rethink everything we do and will be transformative to the way we operate. There is no area of the business which will remain unchanged and all employees will benefit from the Programme, which will bring with it a wide range of new opportunities.

We want to get to a point where continuous improvement is everyone’s responsibility, and we have an engaged workforce which is fully equipped to achieve and maintain best in class operational standards in every area of the company. Our goal is to ensure maximum value for our customers by eliminating all non-value adding activities, whilst ensuring the long-term sustainability of our business for the benefit of our people and our local region.”

Mannok have been awarded a Silver Award at the Repak Pakman Plastic Pledge Awards 2020 in recognition of the company’s extensive work to make their products and operations more sustainable.

The company’s achievements include the development of their ground-breaking flagship solution, Detecta by Mannok, the first fully recyclable black plastic packaging, as well as two other innovative solutions designed to tackle specific recyclability issues, Orbital by Mannok and Signum by Mannok. In the space of just one year, Mannok have emerged as true leaders in the drive to develop more sustainable packaging solutions, with the launch of these three pioneering products and a host of additional sustainability initiatives.

The Pakman awards are the premier national environmental and sustainability awards in Ireland, that recognise excellence in recycling and waste management among businesses, organisations, community groups and initiatives in Ireland.

Due to the impact of Covid-19, this year’s awards did not include the full list of 14 categories seen in previous years, but rather the focus was solely on the Repak Plastic Pledge, with three categories of gold, silver and bronze, and one overall winner. With 125 Plastic Pledge signatories, there was a broad spectrum of organisations represented, and the shortlist included 13 very strong awards entrants.

In addition to Mannok’s Silver Award, the company were among three finalists for the overall Plastic Pledge Award winner, alongside Coca Cola and Aldi, with Aldi picking up the main prize.

Repak’s Plastic Pledge is a comprehensive commitment to reduce plastic packaging waste and help Ireland play its part in achieving the goals set out in the EU Circular Economy Package. The Pledge includes five overarching commitments, each with their own set of measurable targets. These five core commitments are:

1. PREVENT WASTE

Focus on prevention of plastic packaging waste by minimising single use packaging and promoting packaging reuse where possible.

2. SUPPORT CIRCULAR ECONOMY

Support Ireland to deliver the Circular Economy Package plastic recycling targets of 50% of all plastics by 2025 and 55% of all plastic packaging by 2030, as set by the European Commission.

3. SIMPLIFY POLYMERS

Reduce complexity within the plastic packaging supply chain by simplifying polymer usage and eliminating non-recyclable components in all plastic packaging by 2030.

4. USE RECYCLED

Help build a Circular Economy for used plastic packaging by increasing the use of plastic packaging with a recycled content.

5. AVOID FOOD WASTE

Ensure the reductions in use of plastic packaging do not jeopardise our opportunities to achieve Ireland’s goal of a 50% reduction in food waste by 2030 as set out in Ireland’s food waste charter. Plastic plays a role in preserving a large number of food products.

The Plastic Pledge awards criteria challenged signatories of the Pledge to demonstrate results in each of the core commitments. Mannok successfully showed significant achievements to achieve the Silver award, including the move to producing only fully recyclable plastic packaging, the removal of 1,000 tonnes of non-recyclable or difficult to recycle plastics from market, the use of circa 1 billion recycled PET bottles within their operations, and the diversion of 500 tonnes of black plastic packaging from landfill, and all in the space of a year.

Mark McKenna, General Manager of Mannok’s packaging operations, said of this latest award,

“For us, this is a particularly significant achievement. We are serious about our responsibility as plastic packaging producers to ensure everything we do is done in the most sustainable way and to make a significant contribution to the wider community to reduce plastic waste responsibly. The Plastic Pledge we have committed to gives us a comprehensive framework to achieving this and helps us benchmark our progress.

The calibre of the awards entrants shows that we as a company are up there with the very best when it comes to delivering on our sustainability commitments. To achieve a silver award in what is widely recognised as one of the most prestigious awards in the country relating to environmental achievements amongst such a field is fantastic recognition of our work in this area. We’re incredibly proud.”

Mannok have been announced as winners of the Most Innovative Use of Technology Award at the 2020 HR Leadership and Management Awards.

The company’s new Digital Skills Development Programme earned them the award in this highly competitive category, which included a number of high-profile contenders, such as Bus Eireann and LinkedIn, who were named in second and third place respectively.

The Programme has transformed the way Mannok deliver their training through the use of technology and has resulted in significant benefits for both the company and its employees. The Programme was first developed for Mannok’s packaging facility and is now being rolled out across the business.

The HR Leadership and Management Awards celebrate excellence in HR, allowing innovation and achievement to shine, and recognise that it will be key to the future economic prosperity of the Irish economy. The Most Innovative use of Technology category celebrates organisations which have used technology to move HR forward, demonstrating an innovative approach and fully utilising technology to bring benefit.

The announcement comes just days after the company formally rebranded from Quinn to Mannok, with a commitment to continue driving forward in the same progressive manner. This is the latest in a number of awards the company have received in recent years which celebrate their innovative spirit and focus on responsibility to their people, having previously received awards for their innovative Safety Hub and Creating Futures Programme.

Speaking of the latest award win, Caroline McCaffrey, Mannok’s HR Manager, said,

“We’re delighted to receive this recognition of the very innovative work we’ve been doing to completely transform our training delivery and create a structured framework for employees to continually enhance their skills and further their careers.

The implementation of such a vast change requires involvement from every single area of the business, at every level, and the engagement to bring this to fruition is a credit to everyone involved. We continue to expand the Programme to provide further opportunities to employees and to improve efficiency and safety in the workplace.

With both innovation and people so central to the Mannok brand, it is fitting that the very first award we take home under our new name is in recognition of the innovative work we’re doing for the people in the business. And it is the people who deserve to be congratulated for this award win. It is a fantastic achievement for them and for the company.”