Baking & Snack - August 2019 - 146

CONTINUOUS IMPROVEMENT

the output. Finding that peak is sometimes about learning the hard way."

Locking in the info

Efficiency must be
considered from the
time ingredients enter
the mixer to the time
product is packaged.
Vito Palmisano Photography

In today's world a smooth operation is all about the data.
Baking is a combination of art and science, and information is the balancing factor. For continuous improvement, tools such as centerlining, rate lock and statistical
process control (SPC) can help.
"It's about that stability we're trying to get to, and
centerlining is a big tool to gain control of the process,"
Mr. Sloan said.
Operations that run multiple shifts can often fall victim to tweaks that happen from one to the next. Simply
put, centerlining is a methodology that determines the
optimum setting on the line to maximize the efficiency.
It's based on hard data rather than opinions or other
qualitative factors that vary between shifts.
"Centerlining, to me, is about determining what a
production line needs to be doing front-to-back and
knowing that every step of the way has a set of parameters to be monitored, measured and tweaked in order to
maintain that improved level from one day to the next,"
Mr. Dearduff said.
Once a centerline is established, rate locks can be set
according to the standard dictated by the data.
"On weight control, for example, we use systems to
collect data and help us find where we're in a state of
control," Mr. Sloan explained. "Then, as we get more information, we can use the control chart, which provides
instruction to make adjustments, as opposed to falsely

reacting based on judgment. Centerlining is a tool we
use to set the rate lock and maintain a stable area."
The beauty of these tools is that they create repeatable
and predictable outcomes, according to Mr. Owad. Keep
in mind, though, that centerlining establishes a baseline and is not intended to do the work for the operator.
Bakers must take the first steps to ensure operation gets
to its ideal state.
"Optimize the line before setting the centerline marks
or settings," Mr. Owad advised. "Once the centerlines
and rates are set, the program should include a way to
monitor, assess and even adjust parameters where necessary to achieve that ongoing efficiency."
The shortest path between two points is a straight
line, and data helps operators avoid taking detours. SPC
control charts display data that's being analyzed via software in real time. This is a big tool in Clif Bar production. "We have graphs and video boards out on the shop
floor," Mr. Sloan said. "These charts show instructions
that are based on not one data point but a collection of
data where the math suggests something in the process
is heading out of control."

The people factor
There are several data-driven continuous improvement
tools intended to provide quantitative information that
sets the basis for effective, repeatable results without
risk of human error. But that doesn't mean the human
resource can be eliminated.
Continuous improvement is a journey with no finish
line, and it needs people to navigate. Bakers play a critical role in maintaining efficiency and perpetuating a culture of continuous improvement.
"There's a significant benefit to provide the required
knowledge and training for operators and maintenance
personnel to truly understand the line flexibility in an
effective manner," Mr. Owad said. "This knowledge is
powerful, and the associates closest to the line are the
key to optimizing for ongoing line performance results."
Mr. Dearduff cautioned that without a properly
trained workforce, continuous improvement programs
aren't sustainable. "Having people selected for specific
positions, trained well and engaged in what they're doing is one of the fastest routes to good efficiency," he said.
Onboarding, training and proper resources are vital
to the longevity of a continuous improvement program.
"Our team members must first have their hearts and
minds connected to what they do," Mr. Sloan said. "They
need access to real-time data to manage daily goals and
the tools to take action and deliver results. Training,
trusted data, display boards, SPC and the ability to collaborate on the shop floor are all fundamental to maintaining that controlled, stable, calm production line."

*

146 Baking & Snack August 2019 / www.bakingandsnack.com


http://www.bakingandsnack.com

Baking & Snack - August 2019

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

Baking & Snack - August 2019
Contents
Contents
Editorial - A tale of two bakeries
Newsfront - Great Harvest testing home bread delivery
General Mills shifts focus to speed to market
Bunge in partnership to measure sustainability
News - Five trends impacting bakery and snack packaging
Atlas Holdings to purchase snacks unit from TreeHouse
Multivac acquires Fritsch Group
Middleby acquires Packaging Progressions
Ferrero to acquire Campbell Soup’s Kelsen Group
People/In Brief
Food Safety Series - the ALLERGEN piece
Klosterman Baking Co. - ANOTHER HISTORIC MILESTONE
Creating a buzz around a cause
Chabaso - the influential Loaf
Chabaso’s wheat seminar meets ‘ag in the middle’
International Series: Europe - NO TASTE LIKE HOME
Mixes and Bases - ELIMINATING ERRORS
Chocolate - crafting cocoa to expectations
The long road to sustainable cocoa
TECHNICALLY SPEAKING - SANITARY DESIGN made easy
Cake Processing - INTO THIN AIR
Pyler Says: Batter specific gravity
Depanning - CATCH AND RELEASE
ABA takes major step to fight tray theft
Slicing - Making the cut
Continuous Improvement - Good...Better...BEST
Equipment’s role in continuous improvement
Multipacks - Multidimensional MULTIPACKS
Putting the variety in multipacks
Vehicles - efficiency ON THE ROAD
ABA heads IBIE logistics conference
The future of commercial vehicles
SANITATION STRATEGIES - EXPANDING 5S
INDUSTRY IMAGES: IFT - the future is NOW
INDUSTRY IMAGES: BEMA - ALL-TIME HIGH
Meeting Preview: CASBA - Worthy Celebration
The Kit Murphy Memorial Scholarship
Meeting Preview: IBIE - THE TIME HAS COME
Meeting Preview: ABA Technical Conference - EMPOWERING BAKERS
Events
Featured Innnovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
MARKETPLACE
AD INDEX
AD INDEX
NEW PRODUCT SPOTLIGHT
Baking & Snack - August 2019 - Baking & Snack - August 2019
Baking & Snack - August 2019 - Baking & Snack - August 2019
Baking & Snack - August 2019 - FC - 1
Baking & Snack - August 2019 - FC - 2
Baking & Snack - August 2019 - 2
Baking & Snack - August 2019 - 3
Baking & Snack - August 2019 - 4
Baking & Snack - August 2019 - 5
Baking & Snack - August 2019 - 6
Baking & Snack - August 2019 - 7
Baking & Snack - August 2019 - 8
Baking & Snack - August 2019 - Contents
Baking & Snack - August 2019 - 10
Baking & Snack - August 2019 - Contents
Baking & Snack - August 2019 - Editorial - A tale of two bakeries
Baking & Snack - August 2019 - 13
Baking & Snack - August 2019 - 14
Baking & Snack - August 2019 - 15
Baking & Snack - August 2019 - Bunge in partnership to measure sustainability
Baking & Snack - August 2019 - 17
Baking & Snack - August 2019 - Multivac acquires Fritsch Group
Baking & Snack - August 2019 - 19
Baking & Snack - August 2019 - Ferrero to acquire Campbell Soup’s Kelsen Group
Baking & Snack - August 2019 - 21
Baking & Snack - August 2019 - People/In Brief
Baking & Snack - August 2019 - 23
Baking & Snack - August 2019 - 24
Baking & Snack - August 2019 - 25
Baking & Snack - August 2019 - 26
Baking & Snack - August 2019 - Food Safety Series - the ALLERGEN piece
Baking & Snack - August 2019 - 28
Baking & Snack - August 2019 - 29
Baking & Snack - August 2019 - 30
Baking & Snack - August 2019 - 31
Baking & Snack - August 2019 - 32
Baking & Snack - August 2019 - 33
Baking & Snack - August 2019 - 34
Baking & Snack - August 2019 - 35
Baking & Snack - August 2019 - 36
Baking & Snack - August 2019 - 37
Baking & Snack - August 2019 - Klosterman Baking Co. - ANOTHER HISTORIC MILESTONE
Baking & Snack - August 2019 - 39
Baking & Snack - August 2019 - 40
Baking & Snack - August 2019 - 41
Baking & Snack - August 2019 - 42
Baking & Snack - August 2019 - 43
Baking & Snack - August 2019 - 44
Baking & Snack - August 2019 - 45
Baking & Snack - August 2019 - 46
Baking & Snack - August 2019 - 47
Baking & Snack - August 2019 - 48
Baking & Snack - August 2019 - 49
Baking & Snack - August 2019 - Creating a buzz around a cause
Baking & Snack - August 2019 - 51
Baking & Snack - August 2019 - 52
Baking & Snack - August 2019 - 53
Baking & Snack - August 2019 - 54
Baking & Snack - August 2019 - 55
Baking & Snack - August 2019 - 56
Baking & Snack - August 2019 - Chabaso - the influential Loaf
Baking & Snack - August 2019 - 58
Baking & Snack - August 2019 - 59
Baking & Snack - August 2019 - 60
Baking & Snack - August 2019 - 61
Baking & Snack - August 2019 - Chabaso’s wheat seminar meets ‘ag in the middle’
Baking & Snack - August 2019 - 63
Baking & Snack - August 2019 - 64
Baking & Snack - August 2019 - 65
Baking & Snack - August 2019 - 66
Baking & Snack - August 2019 - 67
Baking & Snack - August 2019 - 68
Baking & Snack - August 2019 - International Series: Europe - NO TASTE LIKE HOME
Baking & Snack - August 2019 - 70
Baking & Snack - August 2019 - 71
Baking & Snack - August 2019 - 72
Baking & Snack - August 2019 - 73
Baking & Snack - August 2019 - 74
Baking & Snack - August 2019 - 75
Baking & Snack - August 2019 - 76
Baking & Snack - August 2019 - 77
Baking & Snack - August 2019 - 78
Baking & Snack - August 2019 - Mixes and Bases - ELIMINATING ERRORS
Baking & Snack - August 2019 - 80
Baking & Snack - August 2019 - 81
Baking & Snack - August 2019 - 82
Baking & Snack - August 2019 - 83
Baking & Snack - August 2019 - 84
Baking & Snack - August 2019 - 85
Baking & Snack - August 2019 - 86
Baking & Snack - August 2019 - 87
Baking & Snack - August 2019 - 88
Baking & Snack - August 2019 - 89
Baking & Snack - August 2019 - 90
Baking & Snack - August 2019 - 91
Baking & Snack - August 2019 - 92
Baking & Snack - August 2019 - 93
Baking & Snack - August 2019 - 94
Baking & Snack - August 2019 - Chocolate - crafting cocoa to expectations
Baking & Snack - August 2019 - The long road to sustainable cocoa
Baking & Snack - August 2019 - 97
Baking & Snack - August 2019 - 98
Baking & Snack - August 2019 - 99
Baking & Snack - August 2019 - 100
Baking & Snack - August 2019 - 101
Baking & Snack - August 2019 - 102
Baking & Snack - August 2019 - 103
Baking & Snack - August 2019 - 104
Baking & Snack - August 2019 - TECHNICALLY SPEAKING - SANITARY DESIGN made easy
Baking & Snack - August 2019 - 106
Baking & Snack - August 2019 - Cake Processing - INTO THIN AIR
Baking & Snack - August 2019 - 108
Baking & Snack - August 2019 - 109
Baking & Snack - August 2019 - 110
Baking & Snack - August 2019 - 111
Baking & Snack - August 2019 - 112
Baking & Snack - August 2019 - 113
Baking & Snack - August 2019 - Pyler Says: Batter specific gravity
Baking & Snack - August 2019 - 115
Baking & Snack - August 2019 - 116
Baking & Snack - August 2019 - 117
Baking & Snack - August 2019 - 118
Baking & Snack - August 2019 - Depanning - CATCH AND RELEASE
Baking & Snack - August 2019 - 120
Baking & Snack - August 2019 - ABA takes major step to fight tray theft
Baking & Snack - August 2019 - 122
Baking & Snack - August 2019 - 123
Baking & Snack - August 2019 - 124
Baking & Snack - August 2019 - 125
Baking & Snack - August 2019 - 126
Baking & Snack - August 2019 - 127
Baking & Snack - August 2019 - 128
Baking & Snack - August 2019 - Slicing - Making the cut
Baking & Snack - August 2019 - 130
Baking & Snack - August 2019 - 131
Baking & Snack - August 2019 - 132
Baking & Snack - August 2019 - 133
Baking & Snack - August 2019 - 134
Baking & Snack - August 2019 - 135
Baking & Snack - August 2019 - 136
Baking & Snack - August 2019 - 137
Baking & Snack - August 2019 - 138
Baking & Snack - August 2019 - Continuous Improvement - Good...Better...BEST
Baking & Snack - August 2019 - 140
Baking & Snack - August 2019 - 141
Baking & Snack - August 2019 - 142
Baking & Snack - August 2019 - 143
Baking & Snack - August 2019 - Equipment’s role in continuous improvement
Baking & Snack - August 2019 - 145
Baking & Snack - August 2019 - 146
Baking & Snack - August 2019 - 147
Baking & Snack - August 2019 - 148
Baking & Snack - August 2019 - Multipacks - Multidimensional MULTIPACKS
Baking & Snack - August 2019 - Putting the variety in multipacks
Baking & Snack - August 2019 - 151
Baking & Snack - August 2019 - 152
Baking & Snack - August 2019 - 153
Baking & Snack - August 2019 - Vehicles - efficiency ON THE ROAD
Baking & Snack - August 2019 - ABA heads IBIE logistics conference
Baking & Snack - August 2019 - The future of commercial vehicles
Baking & Snack - August 2019 - 157
Baking & Snack - August 2019 - 158
Baking & Snack - August 2019 - SANITATION STRATEGIES - EXPANDING 5S
Baking & Snack - August 2019 - 160
Baking & Snack - August 2019 - INDUSTRY IMAGES: IFT - the future is NOW
Baking & Snack - August 2019 - 162
Baking & Snack - August 2019 - 163
Baking & Snack - August 2019 - 164
Baking & Snack - August 2019 - INDUSTRY IMAGES: BEMA - ALL-TIME HIGH
Baking & Snack - August 2019 - 166
Baking & Snack - August 2019 - 167
Baking & Snack - August 2019 - 168
Baking & Snack - August 2019 - 169
Baking & Snack - August 2019 - Meeting Preview: CASBA - Worthy Celebration
Baking & Snack - August 2019 - The Kit Murphy Memorial Scholarship
Baking & Snack - August 2019 - 172
Baking & Snack - August 2019 - Meeting Preview: IBIE - THE TIME HAS COME
Baking & Snack - August 2019 - 174
Baking & Snack - August 2019 - 175
Baking & Snack - August 2019 - 176
Baking & Snack - August 2019 - Meeting Preview: ABA Technical Conference - EMPOWERING BAKERS
Baking & Snack - August 2019 - Events
Baking & Snack - August 2019 - 179
Baking & Snack - August 2019 - 180
Baking & Snack - August 2019 - 181
Baking & Snack - August 2019 - Featured Innnovation Center
Baking & Snack - August 2019 - 183
Baking & Snack - August 2019 - Ingredients & Formulating
Baking & Snack - August 2019 - 185
Baking & Snack - August 2019 - 186
Baking & Snack - August 2019 - 187
Baking & Snack - August 2019 - 188
Baking & Snack - August 2019 - 189
Baking & Snack - August 2019 - Equipment & Packaging
Baking & Snack - August 2019 - 191
Baking & Snack - August 2019 - 192
Baking & Snack - August 2019 - 193
Baking & Snack - August 2019 - 194
Baking & Snack - August 2019 - 195
Baking & Snack - August 2019 - 196
Baking & Snack - August 2019 - 197
Baking & Snack - August 2019 - Patents
Baking & Snack - August 2019 - 199
Baking & Snack - August 2019 - 200
Baking & Snack - August 2019 - 201
Baking & Snack - August 2019 - New on the Shelf
Baking & Snack - August 2019 - 203
Baking & Snack - August 2019 - 204
Baking & Snack - August 2019 - 205
Baking & Snack - August 2019 - MARKETPLACE
Baking & Snack - August 2019 - 207
Baking & Snack - August 2019 - 208
Baking & Snack - August 2019 - 209
Baking & Snack - August 2019 - 210
Baking & Snack - August 2019 - 211
Baking & Snack - August 2019 - 212
Baking & Snack - August 2019 - 213
Baking & Snack - August 2019 - 214
Baking & Snack - August 2019 - 215
Baking & Snack - August 2019 - AD INDEX
Baking & Snack - August 2019 - AD INDEX
Baking & Snack - August 2019 - NEW PRODUCT SPOTLIGHT
Baking & Snack - August 2019 - 219
Baking & Snack - August 2019 - 220
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