How Waupaca Foundry Connected Nearly 3,000 Frontline Employees and Reached 85% Adoption

The Challenge: When a shutdown exposed a critical communication gap

When the snowstorm forced Waupaca Foundry to shut down operations across multiple plants, the shutdown itself was manageable. Communicating it was not.

Nearly 3,000 employees needed immediate updates, but many could not be reached through company email or internal systems. The team relied on phone calls and social media, but those channels could not deliver information quickly or consistently to everyone.

“That storm really exposed how unprepared we were to reach everyone quickly, especially the people who needed it most.”

The experience made one thing clear: Waupaca Foundry needed a communication channel designed for its frontline workforce.

The Strategic Shift: From emergency alerts to direct frontline communication

In early 2019, Waupaca Foundry launched theEMPLOYEEapp by Engagedly to establish a direct connection with employees across its plants.

The rollout began with approximately 10% of the workforce. Instead of introducing the platform everywhere at once, the team followed a phased approach, onboarding one plant at a time and supporting adoption through clear communication and incentives.

By the end of the first year, more than half of the workforce was actively using the app.

Then came 2020.

During the pandemic, the platform became a critical source of information for:

• Schedule changes
• Health and safety updates
• Plant announcements
• Direct messages from the CEO

“That period changed everything. People started relying on the app because it gave them clarity and consistency when things were uncertain.”

Adoption reached 85%. Employees used the app not because it was mandatory, but because it had become essential.

The Impact: A Core Part of the Frontline Experience

By 2021, the app was no longer simply a communication tool. It had become part of how Waupaca Foundry operates, shares information, and builds culture across its plants.

Every new employee is now introduced to the platform during onboarding, making it part of the employee experience from the first day.

Today, company wide usage remains strong at 70%, with the app woven into everyday life on the plant floor.

Employees use it to:

• Check shift schedules without relying on bulletin boards
• Access policies and benefits information at any time
• Receive urgent plant and safety updates
• Celebrate work anniversaries, retirements, and other milestones
• Watch business updates directly from company leadership

“Before, if you weren’t on email, you didn’t hear from leadership. Now, every employee, deskless or not, can watch business updates on their phone.”

Regular CEO video messages have become more than business updates. They represent greater visibility, transparency, and inclusion across the organization.

The platform has helped close the communication gap between office employees and frontline teams, giving every employee access to the same important information.

Personalized Communication That Respects Local Culture

One of the platform’s greatest strengths at Waupaca Foundry is its flexibility.

Each plant and team has its own communication preferences. Rather than imposing the same approach everywhere, the platform allows local teams to share information in ways that work for their employees.

Some teams reserve push notifications for urgent alerts. Others use them more regularly for shift schedules, benefit reminders, and HR announcements.

Across locations, teams also use the platform to recognize retirements, anniversaries, and personal milestones, helping employees feel seen and valued.

“The culture in each area is different, and the app lets us respect that. It’s not top down, it’s relevant.”

This balance between company wide consistency and local relevance has helped Waupaca Foundry sustain adoption over time.

Measurable Outcomes

The impact was immediate and has remained strong:

• 85% peak adoption: Usage surged as employees came to rely on the platform for clear and timely information.
• 70% sustained usage: The platform continues to play an active role in daily communication across the organization.
• Nearly 3,000 employees connected: Frontline employees can receive the same essential updates as office based teams.
• Faster emergency communication: During sudden plant shutdowns, alerts can be sent within seconds, helping employees avoid unnecessary commutes and stay safe.
• Greater leadership visibility: CEO video updates now reach employees who previously had limited access to leadership communication.
• Reduced HR workload: Employees can find policies, benefits information, and common resources independently.
• Stronger participation: Employees comment on posts, respond to updates, and engage with company news directly through the platform.

Cultural and Operational Impact

The platform has changed more than how Waupaca Foundry distributes information. It has strengthened how employees experience the organization.

The shift introduced:

• Direct communication instead of reliance on informal channels
• Faster updates during operational disruptions
• Equal access for office and frontline employees
• Greater visibility for company leadership
• More consistent recognition across locations
• Communication tailored to the culture of each plant

Employees are more informed about what is happening, better connected to leadership, and more involved in the life of the organization.

“It’s made a real difference. Our people are more informed, more connected, and more engaged. That’s the kind of impact that lasts.”

Austin, Waupaca Foundry

What This Means for Manufacturing Leaders

In manufacturing, communication gaps can quickly become operational and safety risks. When frontline employees lack access to company email or internal systems, important information may reach them too late or not at all.

Waupaca Foundry addressed that risk by creating a direct, mobile communication channel that employees could access wherever they worked.

What began as a solution for emergency alerts evolved into essential communication infrastructure. The result is faster communication, stronger leadership visibility, reduced pressure on HR, and a workforce that feels more connected to the organization.