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Accounting for more than 1200 personnel, as well as visitors, at any given time, is an arduous task, and even harder in the chaotic environment of an emergency. Every second counts when it comes to the safe evacuation of individuals in such events.
Mustering Roll-Call Automation
When it comes to emergency services and safety, Ferrero has a sweet solution for its chocolate and hazelnut plants, with an automated mustering roll-call system from Litum RTLS. Using just a mobile phone or tablet, and Litum RTLS’s app, safety personnel or managers can identify workers in the case of an evacuation and detect any missing individuals thanks to integration with the company’s time and attendance software.
Client Background
Ferrero Turkey has a strong, global presence selling confectionery products such as Nutella, Tic Tac, and Ferrero Rocher candies in more than 170 countries. In Turkey, the company produces chocolate as well as hazelnut-based products. The company operates two plants in Turkey – a chocolate production facility in Manisa with 400 employees, and its hazelnut plant in Trabzon where another 800 individuals work.
Ferrero needed a way to confirm that all its employees could be safely accounted for when an emergency evacuation was underway. The manual method had gotten out of date — tracking each individual through manual counting was time-consuming and introduced the potential for errors. Even if all personnel appeared at the dedicated mustering points, the employee roster for any given day could not be accurately obtained, especially when visitors were also in the building.
Ferrero takes the safety of these employees seriously and recently saw a solution that leveraged the latest that technology has to offer. The company’s internal audit system requires employee headcounts fast. After all, especially when it comes to evacuation mustering time seconds can be critical when an emergency takes place and people need to be accounted for.
Finding a Solution
Ferrero ruled out using barcode technology since scanning of individual barcodes would be too slow in an emergency. Passive RFID came with its own shortcomings since it requires a reader infrastructure that would need power and a network connection or Wi-Fi. So instead, the company worked with Litum, which offers a Bluetooth Low Energy (BLE) solution for mustering roll-calls that eliminates the need for a fixed infrastructure. With the Automated Emergency Roll-Call system, the company’s safety officials can capture the critical information about who is safe and who might not be, during an emergency, leveraging a simple electronic badge and mobile app.
The Litum Automated Emergency Roll-Call system provides BLE badges powered with batteries that transmit at long distances so that no cables and no hardware installations are needed. Litum RTLS transmits and receives data in real time since mustering time is crucial during emergencies.
With the solution, Ferrero could simply capture employee and visitor location in real time, with a mobile phone or tablet, and the solution software could compare that data against the company’s employee roster which is refreshed periodically from the time and attendance system.
How Mustering Roll-Call Works
With the Litum Automated Emergency Roll-Call system, each employee and visitor is assigned a sleek and lightweight, battery-powered badge. Employee badge IDs connect to details about each individual, securely stored in a cloud server. The link between the badge data and the employee roster is critical as well. As personnel report on site, and as they leave, the employee roster is updated, so that management knows who is on site and who is not. Ferrero can choose how often its employee roster is refreshed in the software settings.
In the event an emergency takes place, safety personnel can retrieve roster information using the Litum App on their cell phone or tablet. The automated emergency evacuation headcount app can provide a list of those within reach and those who are isolated in remote locations, so everyone can be accounted for during evacuation.
As personnel or visitors report to mustering stations, a safety officer at that site uses a cell phone or tablet to capture the BLE signals being transmitted by each badge. Because the badges transmit at a distance—as much as 100 meters, — safety officer can receive and view the data in the roll-call system as soon as the individual approaches the mustering area.
The automated mustering roll-call system integrates with the company’s attendance system so that not only can the headcount be counted against the roster, but the names of those who are onsite and unaccounted for are listed in real time.
The emergency mustering system automatically compares the BLE data captured at the mustering area against the employee rosters and lists each missing individual. Officers can then seek that individual to help ensure they are safely evacuated.
The Results of Automated Mustering Roll-Call
Since its implementation, the Automated Emergency Mustering Roll Call system has revolutionized Ferrero’s approach to evacuation exercises and real-life emergency events. The cumbersome process of using clipboards, paper, and pens in a manual evacuation system is now a thing of the past. With the BLE solution and rapid-response muster times, company management can ascertain within seconds whether all individuals have been safely evacuated or if anyone still needs to be located.
Moreover, the confectionery company’s plants can confidently ensure compliance with regulatory health and occupational safety standards. In addition to automatically counting individuals, the system tracks the frequency and duration of practice exercises, providing comprehensive insights into preparedness.
The deployment of the Litum RTLS roll-call system was swift and hassle-free, requiring no hardware cabling for gateways or readers. Instead, safety personnel utilize their cell phones or tablets to provide critical location data during emergencies, effortlessly. The software seamlessly uploads and downloads essential data from a cloud-based server via a cellular connection.
Since its inception, Ferrero has successfully conducted firefighting exercises by occupational safety regulations. Notably, the time required for full evacuation during these exercises has been significantly reduced, while the accuracy of results has markedly improved.
Solution Designed for Real-Life Problems
Litum RTLS provides a solution that meets the individual needs of each client. While Ferrero requested a mustering system that centers around mobile data capture, technology can also be provided with fixed readers in specific gathering areas or chokepoints.
When used with the mobile app, the solution requires no Wi-Fi or external power; making it flexible, versatile and affordable, while ensuring the company also meets its safety requirements. Ultimately it’s all about safety and saving lives. With automation technology, companies can rest assured their personnel will be accounted for, and never be overlooked in an emergency.
Discover how Ferrero, a global leader in confectionary, took workplace safety to the next level with Litum’s advanced Emergency Mustering Solution. Through this case study, learn how Ferrero’s commitment to innovation and safety translated into a reliable, efficient process for accounting for all employees and visitors during critical moments. Download the full case study to see how Ferrero and Litum partnered to create a safer, more responsive environment that sets a new standard in safety for large-scale facilities.
If you want a mustering roll-call system or emergency evacuation headcount app similar to what we did with Ferrero, feel free to contact us.
