Baking & Snack - April 2019 - 104

MAXIMIZING EFFICIENCY

can imagine, there are hundreds of performance indicators out there, and all the acronyms can be impossible
to remember," observed Rowdy Brixey, president, BEST:
Brixey Engineering Strategies & Training.
Most plants rely on operating equipment effectiveness
(OEE), which measures how well a piece of equipment
or system works compared to its full potential. However,
Mr. Brixey has a few favorites.
One acronym, LBPM-D, stands for "pounds per manhour for direct labor." To determine this KPI, one can
total the gross production pounds for products made on
a line by week, month or another period. Next, divide
this number by the total payroll hours for the direct labor responsible for manufacturing those items during
the same timeframe. "This KPI will show whether you
have extra personnel on the line compared to its historical run rate," Mr. Brixey explained. "This format can also
be used for measuring total plant or any indirect labor.
Trending these numbers can really uncover opportunities for reducing overhead and increasing margin."
Another acronym is YOY CPLB. After calculating
"year-over-year cost per pound" for a specific time period, one can adjust for inflation, raises, utilities and
other variables the operations team typically can't control. Then one can compare the year-over-year numbers
based on waste, scaling, downtime, overtime and other
controllable factors. "Look at 'cost per pound' versus
'cost per unit' because it eliminates factors like loaf size
and bake times," Mr. Brixey advised.

Long and short of it
Such analysis of key data allows bakeries to take a proactive approach in refining their operations. On the
production floor, however, line efficiency can quietly
creep beneath acceptable thresholds set by the bakery.
Crunching such KPIs in real time provides line workers

with the tools to take immediate corrective action, even
if it's a band-aid solution, according Bob White, president of Focus Works.
"The best [system] is having alerts when numbers
reach warning levels such as 85% efficiency," Mr. White
said. "You have to realize that you start at 100% efficiency, and as the day wears on, it can only decrease because
there's no making up for lost time and material."
From an automation standpoint, real-time dashboards give production supervisors and managers the
visual tools to continuously monitor their KPIs and
where they are trending, noted Matt Lueger, vice-president of sales, NorthWind Technical Services. "They
tend to want their data instantaneously, in a snapshot,
through their smartphone or tablet," he said. "Though
[KPIs] may differ slightly from customer to customer,
the big ones that people ask for are production totals, estimated scrap, total yield and energy usage."
However, bakers need to analyze all information with
a proper perspective. "Depending on when they look at
it, those same 'real time' dashboards can be misinterpreted at first," Mr. Lueger pointed out. "Benchmarks are
typically derived over a long time period, so comparing
real-time data to benchmarks can sometimes be scary.
If your data window isn't wide enough, say during a line
startup when scrap is higher, the numbers can be pretty misleading."
That's why Orlando Baking picks 85% as its realistic performance production efficiency goal, whether
it's measured in pounds of product or cases packed. "If
it's 85% or higher, employees will write that number in
green," Mr. Stiffler said. "If it's 84% or lower, they write
it in red."
To accurately monitor waste, for instance, Orlando
Baking tracks it not only per hour but also per shift.
"Let's say our goal is 50 lb or less waste per hour or up

Nothing fake about AI's potential
When it comes to artificial intelligence (AI), the smart money is
betting that the industry might be
closer than many people realize,
noted Matt Lueger, vice-president of
sales, NorthWind Technical Services.
He said that Rockwell Automation
recently purchased Emulate3D,
an engineering software firm that
allows manufacturers to virtually
simulate equipment and systems to
ensure throughput, machine performance and control testing. "Though

104 Baking & Snack April 2019 / www.bakingandsnack.com

artificial intelligence is not widely
used yet in the industry, machine
builders are already starting to incorporate these types of simulations
for virtual reality demos and training
applications," Mr. Lueger said.
Rowdy Brixey, president, BEST:
Brixey Engineering Strategies &
Training, observed that successful
AI depends on accumulating accurate data points to drive decisionmaking. "Providing the proper data
is available, then you must decide

what you'll do with the decision the
data tells you to make," he explained. "A good system integrator
will normally be needed to update
existing equipment."
At the International Baking
Industry Exposition, to be held
Sept. 7-11 in Las Vegas, Mr. Brixey
recommended that bakers ask suppliers how AI is used in their latest
systems displayed at the show. That
will provide new insights that many
bakers likely hadn't seen before.


http://www.bakingandsnack.com

Baking & Snack - April 2019

Table of Contents for the Digital Edition of Baking & Snack - April 2019

Baking&Snack - April 2019
Contents
Contents
Editorial - Bread and butterflies
Newsfront - Grupo Bimbo, Kellogg, PepsiCo recognized for ethics
Walmart taking steps to drive grocery business
ADM, Cargill launch digital grain marketing venture
Global Bakeries expands in sweet goods category
News - RBS partners with Belgian snack systems supplier
Corbion to acquire Brazilian bakery ingredient company
In Memoriam
People/In Brief
Health & Wellness - HEALTH KICK
Are package callouts still effective?
Leclerc Foods - BAKING without compromise
Early adopting for better operations
Brand Loyalty - Digital DISCIPLES
Share it, and they will follow
Starches - DEMYSTIFYING THE MAGIC
Getting away from gluten
Fats & Oils - AN EXPANDED BOX
Collaborating to innovate
SANITATION STRATEGIES - REVISITING GOLDEN RULES
Cookie Processing - Cookie conundrums
Ovens - OPTIMIZED BAKING
Constructed for efficiency
Baking under pressure
Conveying - no STOPPING it now
Keeping the conveyor belt clean
Maximizing Efficiency - IN THE ZONE
Nothing fake about AI’s potential
Secondary Packaging - THINK INSIDE THE box
Industry Images - THE FUTURE IS NOW
Meeting Preview - FOUNTAIN OF KNOWLEDGE
Events
Featured Innovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
MARKETPLACE
AD INDEX
Baking & Snack - April 2019 - Baking&Snack - April 2019
Baking & Snack - April 2019 - Baking&Snack - April 2019
Baking & Snack - April 2019 - 2
Baking & Snack - April 2019 - 3
Baking & Snack - April 2019 - 4
Baking & Snack - April 2019 - 5
Baking & Snack - April 2019 - 6
Baking & Snack - April 2019 - 7
Baking & Snack - April 2019 - 8
Baking & Snack - April 2019 - Contents
Baking & Snack - April 2019 - 10
Baking & Snack - April 2019 - Editorial - Bread and butterflies
Baking & Snack - April 2019 - 12
Baking & Snack - April 2019 - 13
Baking & Snack - April 2019 - 14
Baking & Snack - April 2019 - 15
Baking & Snack - April 2019 - Global Bakeries expands in sweet goods category
Baking & Snack - April 2019 - 17
Baking & Snack - April 2019 - In Memoriam
Baking & Snack - April 2019 - 19
Baking & Snack - April 2019 - People/In Brief
Baking & Snack - April 2019 - 21
Baking & Snack - April 2019 - 22
Baking & Snack - April 2019 - Health & Wellness - HEALTH KICK
Baking & Snack - April 2019 - Are package callouts still effective?
Baking & Snack - April 2019 - 25
Baking & Snack - April 2019 - 26
Baking & Snack - April 2019 - 27
Baking & Snack - April 2019 - 28
Baking & Snack - April 2019 - 29
Baking & Snack - April 2019 - 30
Baking & Snack - April 2019 - Leclerc Foods - BAKING without compromise
Baking & Snack - April 2019 - 32
Baking & Snack - April 2019 - 33
Baking & Snack - April 2019 - 34
Baking & Snack - April 2019 - 35
Baking & Snack - April 2019 - Early adopting for better operations
Baking & Snack - April 2019 - 37
Baking & Snack - April 2019 - 38
Baking & Snack - April 2019 - 39
Baking & Snack - April 2019 - 40
Baking & Snack - April 2019 - 41
Baking & Snack - April 2019 - 42
Baking & Snack - April 2019 - 43
Baking & Snack - April 2019 - 44
Baking & Snack - April 2019 - Brand Loyalty - Digital DISCIPLES
Baking & Snack - April 2019 - Share it, and they will follow
Baking & Snack - April 2019 - 47
Baking & Snack - April 2019 - 48
Baking & Snack - April 2019 - 49
Baking & Snack - April 2019 - 50
Baking & Snack - April 2019 - 51
Baking & Snack - April 2019 - Starches - DEMYSTIFYING THE MAGIC
Baking & Snack - April 2019 - 53
Baking & Snack - April 2019 - 54
Baking & Snack - April 2019 - 55
Baking & Snack - April 2019 - Getting away from gluten
Baking & Snack - April 2019 - 57
Baking & Snack - April 2019 - 58
Baking & Snack - April 2019 - Fats & Oils - AN EXPANDED BOX
Baking & Snack - April 2019 - 60
Baking & Snack - April 2019 - 61
Baking & Snack - April 2019 - 62
Baking & Snack - April 2019 - 63
Baking & Snack - April 2019 - 64
Baking & Snack - April 2019 - 65
Baking & Snack - April 2019 - Collaborating to innovate
Baking & Snack - April 2019 - 67
Baking & Snack - April 2019 - 68
Baking & Snack - April 2019 - SANITATION STRATEGIES - REVISITING GOLDEN RULES
Baking & Snack - April 2019 - 70
Baking & Snack - April 2019 - Cookie Processing - Cookie conundrums
Baking & Snack - April 2019 - 72
Baking & Snack - April 2019 - 73
Baking & Snack - April 2019 - 74
Baking & Snack - April 2019 - 75
Baking & Snack - April 2019 - 76
Baking & Snack - April 2019 - 77
Baking & Snack - April 2019 - 78
Baking & Snack - April 2019 - Ovens - OPTIMIZED BAKING
Baking & Snack - April 2019 - Constructed for efficiency
Baking & Snack - April 2019 - 81
Baking & Snack - April 2019 - 82
Baking & Snack - April 2019 - 83
Baking & Snack - April 2019 - Baking under pressure
Baking & Snack - April 2019 - 85
Baking & Snack - April 2019 - 86
Baking & Snack - April 2019 - 87
Baking & Snack - April 2019 - 88
Baking & Snack - April 2019 - 89
Baking & Snack - April 2019 - 90
Baking & Snack - April 2019 - 91
Baking & Snack - April 2019 - 92
Baking & Snack - April 2019 - 93
Baking & Snack - April 2019 - 94
Baking & Snack - April 2019 - Conveying - no STOPPING it now
Baking & Snack - April 2019 - 96
Baking & Snack - April 2019 - 97
Baking & Snack - April 2019 - Keeping the conveyor belt clean
Baking & Snack - April 2019 - 99
Baking & Snack - April 2019 - 100
Baking & Snack - April 2019 - 101
Baking & Snack - April 2019 - 102
Baking & Snack - April 2019 - Maximizing Efficiency - IN THE ZONE
Baking & Snack - April 2019 - Nothing fake about AI’s potential
Baking & Snack - April 2019 - 105
Baking & Snack - April 2019 - 106
Baking & Snack - April 2019 - 107
Baking & Snack - April 2019 - 108
Baking & Snack - April 2019 - Secondary Packaging - THINK INSIDE THE box
Baking & Snack - April 2019 - 110
Baking & Snack - April 2019 - 111
Baking & Snack - April 2019 - 112
Baking & Snack - April 2019 - 113
Baking & Snack - April 2019 - 114
Baking & Snack - April 2019 - Industry Images - THE FUTURE IS NOW
Baking & Snack - April 2019 - 116
Baking & Snack - April 2019 - 117
Baking & Snack - April 2019 - 118
Baking & Snack - April 2019 - 119
Baking & Snack - April 2019 - 120
Baking & Snack - April 2019 - 121
Baking & Snack - April 2019 - 122
Baking & Snack - April 2019 - Meeting Preview - FOUNTAIN OF KNOWLEDGE
Baking & Snack - April 2019 - Events
Baking & Snack - April 2019 - 125
Baking & Snack - April 2019 - 126
Baking & Snack - April 2019 - 127
Baking & Snack - April 2019 - Featured Innovation Center
Baking & Snack - April 2019 - 129
Baking & Snack - April 2019 - Ingredients & Formulating
Baking & Snack - April 2019 - 131
Baking & Snack - April 2019 - 132
Baking & Snack - April 2019 - 133
Baking & Snack - April 2019 - Equipment & Packaging
Baking & Snack - April 2019 - 135
Baking & Snack - April 2019 - 136
Baking & Snack - April 2019 - 137
Baking & Snack - April 2019 - Patents
Baking & Snack - April 2019 - 139
Baking & Snack - April 2019 - 140
Baking & Snack - April 2019 - New on the Shelf
Baking & Snack - April 2019 - 142
Baking & Snack - April 2019 - MARKETPLACE
Baking & Snack - April 2019 - 144
Baking & Snack - April 2019 - 145
Baking & Snack - April 2019 - 146
Baking & Snack - April 2019 - 147
Baking & Snack - April 2019 - 148
Baking & Snack - April 2019 - 149
Baking & Snack - April 2019 - 150
Baking & Snack - April 2019 - 151
Baking & Snack - April 2019 - 152
Baking & Snack - April 2019 - AD INDEX
Baking & Snack - April 2019 - 154
Baking & Snack - April 2019 - 155
Baking & Snack - April 2019 - 156
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-october-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-september-2021
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http://digitalbs.bakingbusiness.com/sosland/bs/2018_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_11_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2018_03_01
https://www.nxtbook.com/sosland/bs/2018_02_01
https://www.nxtbook.com/sosland/bs/2017_12_01
https://www.nxtbook.com/sosland/bs/2017_11_01
https://www.nxtbook.com/sosland/bs/2017_10_01
https://www.nxtbook.com/sosland/bs/2017_09_01
https://www.nxtbook.com/sosland/bs/2017_08_01
https://www.nxtbook.com/sosland/bs/2017_07_01
https://www.nxtbook.com/sosland/bs/2017_06_01
https://www.nxtbook.com/sosland/bs/2017_05_01
https://www.nxtbook.com/sosland/bs/2017_04_01
https://www.nxtbook.com/sosland/bs/2017_03_01
https://www.nxtbook.com/sosland/bs/2017_02_01
https://www.nxtbook.com/sosland/bs/2016_12_01
https://www.nxtbook.com/sosland/bs/2016_11_01
https://www.nxtbook.com/sosland/bs/2016_10_01
https://www.nxtbook.com/sosland/bs/2016_09_01
https://www.nxtbook.com/sosland/bs/2016_08_01
https://www.nxtbook.com/sosland/bs/2016_07_01
https://www.nxtbook.com/sosland/bs/2016_06_01
https://www.nxtbook.com/sosland/bs/2016_05_01
https://www.nxtbook.com/sosland/bs/2016_04_01
https://www.nxtbook.com/sosland/bs/2016_03_01
https://www.nxtbook.com/sosland/bs/2016_02_01
https://www.nxtbook.com/sosland/bs/2015_12_01
https://www.nxtbook.com/sosland/bs/2015_11_01
https://www.nxtbook.com/sosland/bs/2015_10_01
https://www.nxtbook.com/sosland/bs/2015_09_01
https://www.nxtbook.com/sosland/bs/2015_08_01
https://www.nxtbook.com/sosland/bs/2015_07_01
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https://www.nxtbook.com/sosland/bs/2015_05_02
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https://www.nxtbook.com/sosland/bs/2015_03_01
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https://www.nxtbook.com/sosland/bs/2014_12_01
https://www.nxtbook.com/sosland/bs/2014_11_01
https://www.nxtbook.com/sosland/bs/2014_10_01
https://www.nxtbook.com/sosland/bs/2014_09_01
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https://www.nxtbook.com/sosland/bs/2013_12_01
https://www.nxtbook.com/sosland/bs/2013_11_01
https://www.nxtbook.com/sosland/bs/2013_10_01
https://www.nxtbook.com/sosland/bs/2013_09_01
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https://www.nxtbook.com/sosland/bs/2013_03_01
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https://www.nxtbook.com/sosland/bs/2012_12_01
https://www.nxtbook.com/sosland/bs/2012_11_01
https://www.nxtbook.com/sosland/bs/2012_10_01
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https://www.nxtbook.com/sosland/bs/2011_12_01
https://www.nxtbook.com/sosland/bs/2011_11_01
https://www.nxtbook.com/sosland/bs/2011_10_01
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https://www.nxtbook.com/sosland/bs/2010_12_01
https://www.nxtbook.com/sosland/bs/2010_11_01
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