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American Society of Baking Chicago Marriott
March 3, 2014
Improving Bakery Manufacturing Performance How to Identify the
Correct Tools and Develop an Implementation Plan
Continuous Improvement is not about the things you do well thats
work. Continuous improvement is about removing the things that get
in the way of
your work. The headaches, the things that slow you down, thats
what continuous improvement is all about.
- Bruce Hamilton (President; Vice Chair of The Shingo Institute
Board of Governors&
Member of The Shingo Academy & Shingo Examiner)
Why performance improvement is necessary
Increased competition Consumer demands Higher costs of raw
materials and packaging Increased labor costs
Objectives
Categories of performance problems in your bakery Present
available tools for improving manufacturing
performance Selecting the proper tool or combination of tools to
solve
specific problems Developing a targeted implementation plan for
the use of
these tools
Benefits
Enhance associate engagement Reduction of manufacturing costs
Sustainable quality improvements Competitive advantage in the
market place
Categories of performance problems
Training Rework Raw Material Waste Quality Waiting -
Changeovers/Downtime
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The only thing worse than training your employees and having
them leave is not
training them and having them stay. - Henry Ford
Training Aim to develop the knowledge, skills and attitude
necessary
for effective performance of the work Reasons for Training
Product and quality service New technology Role and career
flexibility Cost control Associate retention
Areas of training Knowledge Technical skills Techniques
Rework Mixing/Makeup
Dough re-added to the mixing or make-up process Wrapping
Having to re-code product Re-tie product Re-bag product
Warehouse/Shipping Staging the wrong product in the wrong
area
Raw Material Waste Over scaled ingredients Product giveaway
Overuse of dusting flour Over/under proofed dough Over/under baked
product Damaged products in wrapping
Characteristic: Unbalanced workloads Process flow stops due to
unplanned
interruptions Queues or idle time
Causes: Inconsistent work methods System Interruptions Lack of
process standardization Capacity doesnt match volume Complexity
Training systems
Waiting Changeovers/Downtime Waiting Changeovers/Downtime
Changeovers Scheduling production
accordingly Pan changes Allergen vs. Non Allergen
5S Shop layout Tool accessibility
Downtime Preventive maintenance
leading to Predictive maintenance to avoid equipment wear and
tear
Robust training systems
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Quality Tools for improving manufacturing performance
5S Kaizen Value Stream Map Poka-Yoke Six Sigma
5S
5S is a program to reduce operational steps and improve the
overall
cleanliness of a work area making it safer and more
productive
Sort Set in Order
Shine Standardize Sustain
5 S Checklist
Floors clean Tools stored Gages clean Std WIP Safety Guards
5 S
Unnecessary
MAY 1996 JUNE 1996
JULY 1996
5S Process
From this
To This
5S Example Benefits of 5S
Reducing changeover, & cleaning time Reduce errors in set up
& inventory Reduce waste in:
The amount of space needed for storage Work In Process (WIP) and
Warehouse inventory Searching waste (when items are hard to find)
Motion waste (poorly located equipment & supplies)
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Kaizen
Kai Zen
Change/Improvement Good/Continuous
Kaizen Usually team-based, where the scope and boundaries of a
problem are
clearly defined Implementing do-now solutions through waste
elimination
Stimulate change
Facilitates employee engagement and training/development
Promotes problem solving skills Systematic approach to Lean
production
Value Stream Map Hand drawn map of the process
Used to explain the process and the materials used at each point
of the process
Assists in identifying line efficiency opportunities
(bottlenecks)
Example of Value Stream Map
Benefits of Value Stream Maps Understand details of work flow in
all functional areas to
satisfy customer needs Quantify lead time, travel distance and
resources consumed Vehicle for waste elimination
Poka-Yoke Designing work processes to eliminate error
1. Control Approach Shuts down the process when an error
occurs
Keeps the suspect part in place when an operation is
incomplete
2. Warning Approach Signals the operator to stop the process and
correct the problem
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Poka-Yoke Examples Benefits of Poka-Yoke Control approach
Eliminates the error
Warning Approach Eliminates the potential for error
Six Sigma Methodology to measure and improve companys
performance, practices and systems
Benefits of Six Sigma Assists in measuring, detecting, and
maintaining quality
standards Data collection and decision making Leads to
standardized processes Associate engagement and accountability
Selecting the proper tools to solve specific problems
Example of Training and Rework Utilizing Kaizen, 5S
Example of Raw Material Waste and Quality Utilizing Six
Sigma
Example of Changeovers and Downtime Utilizing Value Stream Map,
Poke Yoke, 5S
Lack of Training Assume there is a newly hired associate with NO
knowledge of a baking process. The associate is not provided with
an in-depth training program and receives 1 week of training
shadowing with another associate. After 1 week of shadowing, the
associate is placed on 3rd shift wrapping, running 2 baggers for an
8 hour shift.
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Rework is created During the 8 hour shift, the other
associates notice that 4,000 units of product has been placed in
the wrong bag due to picking the wrong box
When the associate was trained, he/she grabbed the box from the
area shown by the other associate
The veteran associate understands how to verify the type of
boxes, the new associate does not have the experience
All units must be re-opened with the assistance of the other 2
wrapping associates and placed in the proper bag causing 4 hours of
overtime
Estimated cost of rework =$300 Estimated cost of wasted
packaging =
$200 Total Cost of Rework = $200 + $300
= $500
Utilization of Tools Kaizen Event takes place in the wrapping
department Why? Data is collected and shows Lost Time The
objective: Identify reasons for lost time
Team is assembled including: 2 wrapping associates 1 production
supervisor 1 maintenance associate
Layout of Wrapping Area is created to understand where Lost Time
is occurring
Utilization of Tools The team observes the wrapping process for
a 2 week period
on multiple shifts, they conclude that rework is the main cause
of Lost Time
An average of 1000 loaves have to be reworked per 3 shifts
because of product being placed in the wrong bag
An average of 1 hour is needed to complete the rework after the
associates shift has ended
The kaizen team decides to create an SOP and conduct 5S to
provide clarity of varieties vs. bag types and train all wrapping
associates
Utilization of Tools 5S Needed?!?
Vs.
The newly trained associate and veteran associates had to find
the proper bag type for the appropriate product in this warehouse
during a changeover
Are we setting the associates up for Failure?
5S is implemented, bags are condensed to 1 rack
Organized by variety, usage, and date received
Appropriate signage is posted for each box and variety
Training and Rework Analysis Assume that over a year the
associates have been conducting rework on a daily basis on all 3
shifts 3 hours per day 15 hours per week
Rework = $60,000 Estimated cost of wasted packaging =
$30,000 Total Cost of Rework = $60,000 +
$30,000 = $90,000 per year
5S / Kaizen Implementation Rework is monitored after the 5S
and
Kaizen Study
Rework has been reduced to 0.50 hours per day
Rework = $10,000 Estimated cost of wasted packaging =
$6,000
Total Cost of Rework = $10,000 + $6,000 =
$16,000 per year
Raw Material Waste & Quality Following the previous example
in the wrapping department,
associates are having difficultly bagging product Similar
varieties are coming to wrapping in all different
shapes and sizes Steps need to be taken to reduce or eliminate
the variation of
product coming to the wrap
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Cost of Waste from Variation Assume that non-conforming product
is 1 in every 100 units
Cost of labor and materials Assume 2000 units a day is wasted
Labor and materials = $500 per day Cost of waste per year =
$125,000
Cost to remake product 2000 units of product to remake = $75 per
day Cost per year = $18,000 per year Total cost per year = $18,000
+ $125,000 = $143,000
Implementing Six Sigma Six sigma can be implemented to reduce
variability
within the process Current State:
Key characteristics within the process are not being monitored
and recorded
Associates define quality standards with their own judgments
Efforts to reduce waste is based on perception not data
Implementing Six Sigma Desired State:
Data is recorded and monitored constantly Product complies with
consumer and company standards Decisions are made based on data not
perception to improve quality
and reduce waste Associates understand data and are data driven
to make decisions
Vs.
Implementing Six Sigma Six Sigma is now implemented to reduce
the number of defects in your
bakery, associates are actively engaged and monitor process
control The number of non-conforming units is decreased from 1/100
to 1/1000
Cost of labor and materials Assume 200 units wasted Labor and
materials = $50 per day Waste per year = $12,000 of waste per
year
Cost to remake product 200 Units of product to remake = $7 per
day Cost per year = $1,500 per year
Total cost per year = $14,000 Cost has just decreased from
$143,000 to $14,000 per year
Waiting - Changeovers Assume the process within your bakery
consists of an average of 10 changeovers that are at least 30
minutes long per production day at the divider area. Value Stream
Mapping, 5S, and Poka-Yoke are conducted to reduce changeovers and
downtime.
Cost of Waiting Changeovers/Downtime Assume that you have an
average of 30 minute changeovers
due to different pan types, allergen to non allergen, and
scheduling
Assume that there are 10 changeovers per day
Changeover could cost up to = $400,000 per year in labor and
materials
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Implementing Value Stream Maps It is noticed that during a
changeover that an associate must travel to 5 key areas in order
to change pans and guides
Needed tools are not at the
proper locations for cleaning purposes
Mobile Equipment
Worker
Pallet
Mobile Equipment
Worker
Pallet
Implementing Poka-Yoke/5S Poka-Yoke
This takes the associate an average of 5 minutes to adjust pans
and guides
Solution: All guides are now preset to set
collars 5 minutes has been reduced in
the changeover
5S All tools needed for a
changeover are placed on shadow boards within 5 ft of the
associates work area
The 5S shadow boards reduce the changeovers by 10 minutes
Cost comparison Before
An average of 10 changeovers per production day
An average changeover at the divider is 30 minutes
6 different guides must be set-up taking on average 5
minutes
Tools for divider clean-up are scattered throughout the bake
shop, costing time for the associate to search
Changeover costs = $400,000 per year
After An average of 10 changeovers per
production day Guides are now set automatically
when selecting a variety at the divider
Tools are placed next to the divider on a 5S shadow board
The changeover time changes to an average of 15 minutes
Changeover costs = $200,000 per year
Developing a targeted implementation plan
Understanding if you have in-house resources available to carry
out implementation plan or if consultants are needed
Understanding of the company culture,
associates, and work environment to roll out implementation
plan
Implementation Plan In House Resources
Do your associates have the knowledge needed to implement
improvement tools?
Do your in-house resources have time needed to properly conduct
these tools?
Benefit of utilizing associates with the knowledge of
improvement tools: Understand the processes and
culture within your bakery
Consultants Outsources needed? Consultants provide training
and
implementation Focus all their attention on the
efforts to help you improve Company provides objectives,
consultants provide the knowledge to develop plans for
execution
Consultants are scalable Can contract for variable time
periods
Implementation Roll Out Sponsorship of senior leadership and
plant leadership Alignment with organizational goals Providing
resources necessary to implement tools Selection of key associates
for implementation team
Associate empowerment to provide and carry out plan Monitor team
direction, ensure data driven decisions
Commitment from all associates to engage on tools On-going
communication of project status and results
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Conclusion Importance of improvement in todays competitive
environment Benefits of improving quality, profitability, and
associate
engagement Wide availability of tools, choosing the correct
tools for your
bakery culture Opportunities are inherent in any manufacturing
facility Utilizing the tools available and engaging associates in
the
proper use of these tools will result in productivity and
performance improvements, both in process and associates
Questions?