Bakery Efficiency Initiative
Overview
The client faced operational inefficiencies in staffing and high production downtime, which were driving up operating costs and hampering their ability to operate at peak efficiency. The objective was to streamline resource allocation, reduce waste, and create a culture of accountability for continuous improvement.
Approach
Implemented a shop floor control system to track real-time staffing levels and machine downtime. This system enabled detailed analysis of operational bottlenecks and identified key areas for improvement. Additionally, we established a Continuous Improvement department, integrating data-driven decisions and fostering a culture focused on efficiency and accountability.
Key Contributions
Introduced data collection and performance feedback mechanisms that allowed the team to optimize staffing and reduce production delays. The new Continuous Improvement department led to sustained process optimization and accountability across operations, encouraging long-term commitment to operational excellence.
Impact
Within 6 months, the solutions generated $4.2 million in annual savings through optimized staffing and reduced downtime. The on-hand inventory of finished goods dropped from 14 weeks to 3 weeks, and uptime increased by over 30%. These improvements allowed the bakery to shift from a 7-day to a 5-day schedule, reducing operational strain while increasing efficiency.