Baking & Snack - April 2019 - 106

MAXIMIZING EFFICIENCY

Left: Real-time data allows
bakeries to monitor quality and
ensure product consistency
throughout the process.
Sosland Publishing Company

Right: Bakeries rely on data
management systems to drive
efficiencies and guide them to the
root cause of production issues.
Focus Works

to 400 lb per shift," Mr. Stiffler noted. "If production employees run 49 lb of waste per hour, they would all be
green. But let's say they ran 100 lb of waste on the last
hour; they'd be green all day except for the last hour, and
unfortunately at that point, they would be over for the
shift. The total number then would be red."
Mr. White cautioned that data can be misinterpreted
and the problem misunderstood. For example, the information may indicate that downtime was caused by
equipment failures when it was really the result of the
cost of unexpected maintenance per piece of equipment.
Or there may be other reasons for underperformance.
"The causes of downtime and waste are not always clearly defined," he said. "The question should be, 'Were the
causes equipment-related or quality-related?' You can't
reduce downtime if you can't get to the root cause."
At Orlando Baking, pre-shift huddles establish awareness about what potential issues might occur and how to
prevent them. "Where we're at right now is driving efficiency against our standards and then making sure that
ownership is there," Mr. Stiffler said. "And every hour,
we're promoting the teams to dig deep, identify root
causes and come up with action plans to make the lines
run better than they were prior to that."
That said, keep in mind that over-analysis can lead
to paralysis, especially if management teams do more
talking than walking. "Many inefficient operations hold
meetings more frequently as things worsen but fail to
truly identify root causes or set strong expectations and
accountability to get problems fixed," Mr. Brixey said.
"Get out on the production floor more, and you might
be surprised what you can discover."

Investing in better performance
Unearthing the root causes of unexpected downtime can
help identify and justify capital investments to enhance
productivity and bolster yield in the long run.
"We find a lot of production teams that consider unplanned downtime to be unavoidable or just a maintenance problem," Mr. Lueger said. "The data is there to
tell you why and how often your plant is down due to

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

failing or improperly used equipment. If you find the
windows of downtime, you will find either a good opportunity for preventative maintenance or an opportunity to retrofit a piece of your system. Both are lowhanging fruit for increased production."
Orlando Baking is harnessing its data to develop
a potential shopping list for the International Baking
Industry Exposition (IBIE), which will be held Sept.
7-11 in Las Vegas. "OEE tells us about our overall
equipment effectiveness, and where we should expand,"
Mr. Stiffler said. "If we needed to expand production in
our plant, it allows us to focus in on how to do that to
free up more space and time."
For identifying specific investments, Mr. Brixey recommended using a capacity report that pinpoints bottlenecks. First, calculate the maximum run rate on each
piece of major equipment to discover the lowest limiting
factor for each product variety or pan. "The best returns
usually come from focusing on the items with the highest volume," he noted. "Most times you'll find that plants
have slowed down their lines to make running easier
versus fixing troublesome equipment."
Capital projects with significant returns often come from
replacing one piece of equipment or a couple of assets that
drastically limit the line's throughout by performing well
below that of many other machines. "The capacity report
and bottleneck findings can lead you to a strong understanding of whether you need to replace select assets or the
entire line," Mr. Brixey explained. "Having this report completed in advance of IBIE can help you maximize how you
spend your time while in 'the land of plenty.' "
Mr. White cautioned bakers against purchasing new
equipment by price comparison alone. "Also consider
the cost of ownership," he suggested. "They should network with other bakers to find out not only the reliability of the equipment but also the ease of maintenance and
repairs and cost/availability of spare parts. Purchasers
should also consider the availability of local service."
Taking everything into consideration is how to
maximize efficiency and attain peak performance
over the long run.

*


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
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-august-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-july-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-june-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-may-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-april-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-march-2021
https://digitalbs.bakingbusiness.com/sosland/bs/baking-snack-february-2021
http://digitalbs.bakingbusiness.com/sosland/bs/2020_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2020_10_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2019_02_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_09_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2018_06_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_05_01
http://digitalbs.bakingbusiness.com/sosland/bs/2018_04_01
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
https://www.nxtbook.com/sosland/bs/2015_06_01
https://www.nxtbook.com/sosland/bs/2015_05_02
https://www.nxtbook.com/sosland/bs/2015_04_01
https://www.nxtbook.com/sosland/bs/2015_03_01
https://www.nxtbook.com/sosland/bs/2015_02_01
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
https://www.nxtbook.com/sosland/bs/2014_08_01
https://www.nxtbook.com/sosland/bs/2014_07_01
https://www.nxtbook.com/sosland/bs/2014_06_01
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https://www.nxtbook.com/sosland/bs/2014_04_01
https://www.nxtbook.com/sosland/bs/2014_03_01
https://www.nxtbook.com/sosland/bs/2014_02_01
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
https://www.nxtbook.com/sosland/bs/2013_08_01
https://www.nxtbook.com/sosland/bs/2013_07_01
https://www.nxtbook.com/sosland/bs/2013_06_01
https://www.nxtbook.com/sosland/bs/2013_05_01
https://www.nxtbook.com/sosland/bs/2013_04_01
https://www.nxtbook.com/sosland/bs/2013_03_01
https://www.nxtbook.com/sosland/bs/2013_02_01
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
https://www.nxtbook.com/sosland/bs/2012_09_01
https://www.nxtbook.com/sosland/bs/2012_08_01
https://www.nxtbook.com/sosland/bs/2012_07_01
https://www.nxtbook.com/sosland/bs/2012_06_01
https://www.nxtbook.com/sosland/bs/2012_05_01
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https://www.nxtbook.com/sosland/bs/2012_03_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
https://www.nxtbook.com/sosland/bs/2010_10_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2005_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2005_09_01
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http://digitalbs.bakingbusiness.com/sosland/bs/2004_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_11_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_10_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_09_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_08_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_07_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_06_01
http://digitalbs.bakingbusiness.com/sosland/bs/2004_05_01
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https://digitalbs.bakingbusiness.com/sosland/bs/2004_03_01
https://digitalbs.bakingbusiness.com/sosland/bs/2004_02_01
https://digitalbs.bakingbusiness.com/sosland/bs/2003_12_01
https://digitalbs.bakingbusiness.com/sosland/bs/2003_11_01
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