Trivium Packaging Scales Global Operational Excellence with Poka
Trivium Packaging, a global leader in sustainable metal packaging, produces cans and containers for the world’s top food, beverage, and personal care brands. With operations spanning 18 countries and 57 sites, the company faced a common challenge in large-scale manufacturing: standardizing processes and capturing best practices across a dispersed global network.
Company Profile
Metal Packaging
~7,400
57
Global (Europe, North & South America, Asia)
800+ leading brands including Nestlé, Unilever, Coca-Cola, and L’Oréal
Trivium’s Global Transformation with Poka
Plants onboarded to Poka
Frontline employees connected
Digital form completions
Work instructions digitized
Issues created and resolved
Skills endorsements achieved
Building a Common Digital Backbone Across 40+ Plants
Trivium Packaging, a global leader in sustainable metal packaging, produces cans and containers for the world’s top food, beverage, and personal care brands. With operations spanning 18 countries and 57 sites, the company faced a common challenge in large-scale manufacturing: standardizing processes and capturing best practices across a dispersed global network.
While some plants had already digitized certain workflows, others relied heavily on paper, Excel files, and localized systems. This fragmentation limited knowledge sharing, slowed problem-solving, and made it difficult to measure performance consistently.
As Central Quality Manager Stephane Albert explained, “We wanted to be a company of the 22nd century - with connected frontline workers who have the knowledge they need at their fingertips.”
To achieve this, Trivium needed a single connected worker platform that could integrate seamlessly into their global quality transformation strategy - enabling every plant to operate with shared standards, digital tools, and transparent performance data.
From Pilot to Global Rollout
Trivium Packagingbegan its Poka journey in 2023 with pilot plants in Leeuwarden and Heerenveen (Netherlands), using a train-the-trainer approach. Once validated, the model was scaled rapidly through five deployment waves, each grouping multiple sites supported by a central expert team. According to the deployment roadmap, the rollout followed this structure:
Pilot (2023 - early 2024): 2 sites
Group 1 (2024): 5 plants onboarded by Trivium experts
Groups 2 - 4 (2025 - 2026): Expansion to 33 additional plants
Group 5 (2026+): Rollout to U.S. plants for a total of 45 sites globally
This phased rollout was managed by a dedicated central project team, including global and local champions - ensuring each plant received weekly coaching, standardized practices, and peer-to-peer support.
Digital Tools Driving Global Standardization
Every Trivium site now uses Poka’s full suite of functionalities:
- Digital Work Instructions: SOPs are digitized, searchable, and accessible on shared tablets across production lines.
- Checklists and Forms: More than 106,000 forms completed - covering audits, safety checks, maintenance routines, and quality verifications.
- Issues Management: Over 2,900 issues logged with structured follow-up, enabling bottom-up communication and real-time problem solving.
- Skills Management: 15,000+ endorsements tracked, ensuring workforce versatility and clear training plans.
These tools are embedded in standardized “Trivium Toolboxes” for Safety, Quality, Operations, Maintenance, and HR, each containing predefined forms, templates, and best practices used company-wide.
Measurable Efficiency and Engagement Gains
By October 2025, 40 Trivium plants had fully implemented Poka - connecting more than 2,100 frontline employees in a unified digital ecosystem.
Operational Impact Highlights:
- >106,000 digital form completions, supporting consistent execution and faster escalation
- >4,300 work instructions created and standardized
- >2,900 issues resolved, reducing downtime and defects through real-time feedback loops
- >15,000 skills endorsements, driving workforce flexibility and a stronger compliance culture
- 2% cost reduction at one large factory - equal to more than €50,000 in annual savings
- SMED improvements delivering 2-hour changeover time reduction
- 10-minute faster truck-loading cycles achieved through optimized workflows
“Poka doesn’t just bring cost savings - it enables us to reach operational excellence. It connects people, performance, and processes,” said Stephane Albert.
Poka became our global reference system. We created a library of best practices that any plant can adopt and adapt in its own language.
Stephane Albert
Central Quality Manager, Trivium Packaging
Keys to Success
Trivium attributes its successful global deployment to several core principles:
- Strong executive sponsorship through an active Steering Committee.
- Empowered local teams with autonomy to define roadmaps aligned to business goals.
- Centralized governance and weekly coaching across all plants.
- A growing Poka User Community sharing best practices and innovation.
- Standardized Toolboxes ensuring quality and safety excellence everywhere.
“We gave plants the freedom to create and adapt - and that creativity made Poka stronger across Trivium,” said Stephane Albert.
A Smarter, Leaner, and Fully Connected Trivium
With Poka now embedded across its global network, Trivium is advancing toward its 2028 vision: a fully connected, learning organization where every employee can access real-time knowledge, insights, and training - all in one platform.
According to Trivium’s five-year roadmap, future milestones include:
- Full integration of Poka with MES, SAP, and maintenance systems (Ultimo, TLM, APC).
- AI-powered analytics to support frontline decision-making.
- Continuous sharing of best practices through a global Poka community
“Our factories are becoming smarter, leaner, and fully connected - with a workforce that’s skilled, confident, and engaged.”
Ready to Empower Your Frontline Like Trivium?
Discover how Poka can help your teams digitize processes, standardize training, and drive operational excellence - at scale. Book a demo with our team today to learn how.