Baking & Snack - September 2019 - 77

INDUSTRY INSIGHT
Jim Kline
jkline@theensolgroup.com

As bakeries expand and modernize, they begin to see that future success is often ...

TIED TO WORKFORCE
I recently had the opportunity to work with the owners
of an industrial bakery who intend to transform their
operations. The goals were straightforward - increase
capacity, optimize manufacturing efficiency, improve
yield, minimize non-value-added labor tasks and reduce operating costs. It wasn't the first time I had heard
those goals for a new bakery or modernization program.
However, while their operational goals may be considered common, their strategic objective did take me by
surprise. Their objective is to improve the quality of life
for employees and their families as a catalyst for achieving a sustainable future. They saw their future tied to
meeting the needs of their workforce: line workers, support personnel and management.
Conversations with employees quickly identified
what they saw as important for improving their quality
of life. First, they wanted a regular work week - days
preferable - that would allow them additional time
with their families; second, a reduction in overtime; and
third, improved working conditions.
Beyond enhancing the quality of life for their workforce, the owners wanted to achieve improved and consistent product quality, better service to market, less
turnover in factory workers, lower cost of goods, becoming an employer of choice and reduced downtime.
Looking down from the 20,000-ft level, the objectives
of the employees and owners mesh well.
If there were sufficient capacity to produce the required volume in a 10-hour shift, a single-shift operation
for the majority of employees would become a reality.
This would also substantially reduce cost by eliminating the second shift. In addition, a single-shift operation
would provide sanitation and maintenance with enough
time to keep equipment in top shape, reducing downtime. Lastly, it would save on utilities, eliminate 24/7 su-

pervision and reduce the need for 24/7 support services.
Certain steps could improve efficiency and enhance
the work environment: increase lighting, improve the
workplace environment, create space to safely move ingredients and finished products, and provide "homes"
for supplies, ingredients and finished products.
Other steps contribute to better process consistency
and less labor intervention. These include minimizing
material handling through automated systems; providing controlled environments for fermentation, retarding
and proofing; automating pan and board handling and
rack loading and unloading.
Beyond the capital expenditure is the investment in
the employees themselves. They need to be equipped
with the knowledge and skills to operate new technology, employ new manufacturing methods and operate a disciplined process. A significant percentage of
the workforce will have the opportunity to move from
performing manual tasks to operating machines, which
requires new skills but also provides a higher level of
compensation.
It is also expected, based on the company's experience, that there will be significantly less turnover at the
operator level, saving numerous soft costs associated
with workforce turnover: reduced cost of hiring, financial impact of a vacancy, the onboarding costs of a new
hire and higher process loss as new skills are learned.
The bakery's ownership is making a smart investment, one that directly addresses employee satisfaction
and recognizes their needs. At the same time, the company is providing the necessary return with ongoing
benefits well beyond the investment period. If you were
challenged to improve the quality of life for your workforce, what do you think they would want? Maybe you
should ask them.

*

www.bakingandsnack.com / September 2019 Baking & Snack 77


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Baking & Snack - September 2019

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

Baking & Snack - September 2019
Contents
Contents
Editorial - Bringing it all to life
Newsfront - Hostess relocating headquarters to Kansas
Martin’s ramps up retail offerings in Canada
Atlas finalizes deal for TreeHouse snacks business
News - Atlas finalizes deal for TreeHouse snacks business
The Hershey Co. invests in snack bar company
Ingredion increasing focus on plant-based proteins
Kraft Heinz to cut 400 jobs
Cain Food Industries names new president, CEO
Rich Products acquires Christie Cookie
AIB International ending projects at headquarters
In memoriam
People/In Brief
Employee Safety - ZEROING IN ON SAFETY
Gold Standard Baking - going for the GOLD
Building a team starts with character
International Series: Middle East - transcending CONTINENTS
Middle East food-based events deliver market opportunities
Assessing the trends down in Africa
Fats & Oils - Beyond FUNCTIONALITY
Plant-Based Protein - alternate routes to PROTEIN
INDUSTRY INSIGHT - TIED TO WORKFORCE
Mixing - TOTALLY MIXED UP
Making it shine by design
Sweet Goods Technology - INNER Beauty
Dividers - DIVIDED by SPEED
A consistently divisive delivery
Run to Failure - RUNNING ON EMPTY
Where proper maintenance begins … and where it’s going
Robotics - the REPLACEMENTS
Events
Featured Innovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
MARKETPLACE
AD INDEX
NEW PRODUCT SPOTLIGHT
Baking & Snack - September 2019 - Baking & Snack - September 2019
Baking & Snack - September 2019 - Baking & Snack - September 2019
Baking & Snack - September 2019 - 2
Baking & Snack - September 2019 - 3
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Baking & Snack - September 2019 - 7
Baking & Snack - September 2019 - 8
Baking & Snack - September 2019 - Contents
Baking & Snack - September 2019 - 10
Baking & Snack - September 2019 - Contents
Baking & Snack - September 2019 - Editorial - Bringing it all to life
Baking & Snack - September 2019 - 13
Baking & Snack - September 2019 - 14
Baking & Snack - September 2019 - 15
Baking & Snack - September 2019 - Atlas finalizes deal for TreeHouse snacks business
Baking & Snack - September 2019 - 17
Baking & Snack - September 2019 - Kraft Heinz to cut 400 jobs
Baking & Snack - September 2019 - 19
Baking & Snack - September 2019 - In memoriam
Baking & Snack - September 2019 - People/In Brief
Baking & Snack - September 2019 - Employee Safety - ZEROING IN ON SAFETY
Baking & Snack - September 2019 - 23
Baking & Snack - September 2019 - 24
Baking & Snack - September 2019 - 25
Baking & Snack - September 2019 - 26
Baking & Snack - September 2019 - 27
Baking & Snack - September 2019 - 28
Baking & Snack - September 2019 - 29
Baking & Snack - September 2019 - Gold Standard Baking - going for the GOLD
Baking & Snack - September 2019 - 31
Baking & Snack - September 2019 - 32
Baking & Snack - September 2019 - 33
Baking & Snack - September 2019 - 34
Baking & Snack - September 2019 - Building a team starts with character
Baking & Snack - September 2019 - 36
Baking & Snack - September 2019 - 37
Baking & Snack - September 2019 - 38
Baking & Snack - September 2019 - 39
Baking & Snack - September 2019 - 40
Baking & Snack - September 2019 - 41
Baking & Snack - September 2019 - 42
Baking & Snack - September 2019 - 43
Baking & Snack - September 2019 - 44
Baking & Snack - September 2019 - International Series: Middle East - transcending CONTINENTS
Baking & Snack - September 2019 - Middle East food-based events deliver market opportunities
Baking & Snack - September 2019 - 47
Baking & Snack - September 2019 - 48
Baking & Snack - September 2019 - 49
Baking & Snack - September 2019 - Assessing the trends down in Africa
Baking & Snack - September 2019 - 51
Baking & Snack - September 2019 - 52
Baking & Snack - September 2019 - 53
Baking & Snack - September 2019 - 54
Baking & Snack - September 2019 - Fats & Oils - Beyond FUNCTIONALITY
Baking & Snack - September 2019 - 56
Baking & Snack - September 2019 - 57
Baking & Snack - September 2019 - 58
Baking & Snack - September 2019 - 59
Baking & Snack - September 2019 - 60
Baking & Snack - September 2019 - 61
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Baking & Snack - September 2019 - 63
Baking & Snack - September 2019 - 64
Baking & Snack - September 2019 - 65
Baking & Snack - September 2019 - 66
Baking & Snack - September 2019 - Plant-Based Protein - alternate routes to PROTEIN
Baking & Snack - September 2019 - 68
Baking & Snack - September 2019 - 69
Baking & Snack - September 2019 - 70
Baking & Snack - September 2019 - 71
Baking & Snack - September 2019 - 72
Baking & Snack - September 2019 - 73
Baking & Snack - September 2019 - 74
Baking & Snack - September 2019 - 75
Baking & Snack - September 2019 - 76
Baking & Snack - September 2019 - INDUSTRY INSIGHT - TIED TO WORKFORCE
Baking & Snack - September 2019 - 78
Baking & Snack - September 2019 - Mixing - TOTALLY MIXED UP
Baking & Snack - September 2019 - 80
Baking & Snack - September 2019 - 81
Baking & Snack - September 2019 - 82
Baking & Snack - September 2019 - 83
Baking & Snack - September 2019 - 84
Baking & Snack - September 2019 - 85
Baking & Snack - September 2019 - Making it shine by design
Baking & Snack - September 2019 - 87
Baking & Snack - September 2019 - 88
Baking & Snack - September 2019 - 89
Baking & Snack - September 2019 - 90
Baking & Snack - September 2019 - Sweet Goods Technology - INNER Beauty
Baking & Snack - September 2019 - 92
Baking & Snack - September 2019 - 93
Baking & Snack - September 2019 - 94
Baking & Snack - September 2019 - 95
Baking & Snack - September 2019 - 96
Baking & Snack - September 2019 - 97
Baking & Snack - September 2019 - 98
Baking & Snack - September 2019 - Dividers - DIVIDED by SPEED
Baking & Snack - September 2019 - 100
Baking & Snack - September 2019 - 101
Baking & Snack - September 2019 - 102
Baking & Snack - September 2019 - 103
Baking & Snack - September 2019 - A consistently divisive delivery
Baking & Snack - September 2019 - 105
Baking & Snack - September 2019 - 106
Baking & Snack - September 2019 - Run to Failure - RUNNING ON EMPTY
Baking & Snack - September 2019 - 108
Baking & Snack - September 2019 - Where proper maintenance begins … and where it’s going
Baking & Snack - September 2019 - 110
Baking & Snack - September 2019 - 111
Baking & Snack - September 2019 - 112
Baking & Snack - September 2019 - 113
Baking & Snack - September 2019 - 114
Baking & Snack - September 2019 - Robotics - the REPLACEMENTS
Baking & Snack - September 2019 - 116
Baking & Snack - September 2019 - 117
Baking & Snack - September 2019 - 118
Baking & Snack - September 2019 - 119
Baking & Snack - September 2019 - Events
Baking & Snack - September 2019 - 121
Baking & Snack - September 2019 - 122
Baking & Snack - September 2019 - 123
Baking & Snack - September 2019 - Featured Innovation Center
Baking & Snack - September 2019 - 125
Baking & Snack - September 2019 - Ingredients & Formulating
Baking & Snack - September 2019 - 127
Baking & Snack - September 2019 - Equipment & Packaging
Baking & Snack - September 2019 - 129
Baking & Snack - September 2019 - 130
Baking & Snack - September 2019 - 131
Baking & Snack - September 2019 - Patents
Baking & Snack - September 2019 - 133
Baking & Snack - September 2019 - New on the Shelf
Baking & Snack - September 2019 - 135
Baking & Snack - September 2019 - MARKETPLACE
Baking & Snack - September 2019 - 137
Baking & Snack - September 2019 - 138
Baking & Snack - September 2019 - 139
Baking & Snack - September 2019 - 140
Baking & Snack - September 2019 - 141
Baking & Snack - September 2019 - 142
Baking & Snack - September 2019 - 143
Baking & Snack - September 2019 - 144
Baking & Snack - September 2019 - AD INDEX
Baking & Snack - September 2019 - NEW PRODUCT SPOTLIGHT
Baking & Snack - September 2019 - 147
Baking & Snack - September 2019 - 148
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