Wholesale Bakery

Challenge

Every day, this wholesale bakery had to completely shut down production to properly clean and sanitize the facility. That cleaning time was a lot of lost dough. The bakery knew if they could get some of that time back, they could make even more doughnuts. They could also improve their standard operating procedures (SOPs), increase morale and reduce turnover.

Veritiv solution

We used our LEAN approach to solve their challenges and discovered several types of waste interfering with cleaning productivity.

• Transportation:: The team had to move and break down production equipment every day.
• Complexity: The staff had not developed standard operating procedures. This led to wasted time.
• Time: Too much time was used to transfer equipment.
• Labor: The staff was using too much equipment to sterilize the facility which led to wasted labor hours.

The result of Veritiv’s LEAN report and the changes made by the bakery led to the same high cleaning standards they had before, but cut cleaning time by three hours every day. That was three additional hours our customer could spend making doughnuts.

Results

Since working with our team, the bakery has boosted their bottom line and brand, with results including:

• An opportunity to increase revenue by $1.3 million in annual revenue.
• Reduced spend across all verticals—more than $50,000 dollars annually in one bakery location alone.
• $19,710 a year in reduced labor costs.
• A three-hour reduction in staff cleaning time, freeing the team up to focus on other efforts.
• Increased production to include additional baked items which they had previously outsourced.
• The highest score they’ve ever achieved from the American Institution of Bakeries.

They are now working with Veritiv at their other locations to expand their production time and revenue.