Tuesday, August 22, 2023

Flower Foods Inc. and Other Bakery and Bread Companies - Productivity Improvement - Industrial Engineering - Cost Reduction Activities

 

Interesting Information on Flower Foods

https://6sense.com/company/flowers-foods/5c3b0353d55ae49f1b7aaa3b





Bimbo Bakeries USA

Drums, Pennsylvania, United States

Training and Productivity Manager

POSTED ON 6/16/2023

AVAILABLE BEFORE 9/22/2023

 Bimbo Bakeries USA Hired Organization Address Breinigsville, PA Full Time

Job Posting for Training and Productivity Manager at Bimbo Bakeries USA

This position is responsible for productivity initiatives and all operational training programs including training in baking and management systems under the supervision of the Plant Manager.




Key Job Responsibilities:


Demonstrates supports of General Bakery Safety, Food Safety, Food Defense initiatives and Good Manufacturing Practices (GMP) and ensures adherence to all quality requirements including Hazard Analysis and Critical Control Points (HACCP), Standard Operating Procedures (SOP’s), etc.

Oversees training for salaried and hourly associates

Leads and owns the On-the-Job training program within the bakery

Approves new training content and changes

Leads the OJT training team, training coordinator in facility reports directly to this leader

Trains and coaches supervisors on baking and management systems in the bakery

Audits procedures and proficiency of systems and associates

Project manager for productivity projects and leads work behind future productivity projects.

Leads Kaizen events in bakery to foster a continuous improvement culture

Provides leadership, training and coaching with associates to create culture of inclusion and engagement.

Responsible for ensuring and maintaining a safe work environment through compliance of all Company, Local, State and Federal mandates or programs.

Create a Continuous Improvement environment by improving products, service, and processes with the objective to reduce waste while striving for efficiency and profitability.

Knowledge of start-up including calculating orders, checking dough sheet, equipment condition and temperature settings.

Must be knowledgeable around procedures outlined in the Food Safety Plan and the Food Quality Plan and any other programs that support the food safety and quality systems and other 3rd party audits.

Ensures compliance with AIB standards, Company policies and government regulations.

May conduct incident investigations, responsible for reporting processes and ensuring any identified preventative actions are completed.

Participates in and drives LEAN manufacturing culture.

Responsible for 3-6 lines (1 or 2 bakeries)

#LI-VB1



Position Requirements:


Key Behavioral Competencies:


Results Achiever

Change Agent

People Oriented Leadership

Learning and Adapting Best Practices

Lives By and Promotes Values


Education and Work History:


High School diploma or equivalent with 5-7 years of supervisory experience in production, preferably in the food processing industry or fast-paced manufacturing environment; OR

College degree with 2-3 years relevant leadership experience

A combination of education, training and experience that results in demonstrated competency to perform the work may be substituted.

Excellent communication skills (verbal and written), including the ability to handle difficult conversations.

Proficiency-level computer skills including MS Office applications. KRONOS knowledge is a plus.

Proficiency-level knowledge of all bakery systems

Strong organization skills and ability to handle multiple tasks/projects.

Willingness to work varied shifts, including nights, weekends, and holidays.

The physical and mental demands described in each job posting are representative of those that must be met by an associate to successfully perform the essential functions of each job. Reasonable accommodations may be requested to enable qualified individuals with disabilities to perform the essential functions of each job.


Bimbo Bakeries USA is an equal opportunity employer with a policy that provides equal employment opportunity for applicants and employees regardless of race, color, religion, sex (including pregnancy, sexual orientation, or gender identity), national origin, age, disability, genetic information, marital status, veteran status, any other classification protected by law.

https://www.salary.com/job/bimbo-bakeries-usa/training-and-productivity-manager/j202212220027334842468


2023


On its efforts to make the business more resilient, McMullion said Flowers is “on track to meet our savings goal of $20m to $30m for 2023”.

https://www.just-food.com/news/flowers-foods-cuts-full-year-guidance-after-slow-start/?cf-view


Process Improvement Engineer

Flowers Foods & Subsidiaries · Nevada, United States (On-site) Reposted  3 weeks ago
Full-time
5,001-10,000 employees · Food and Beverage Manufacturing

About the job
The Process Improvement Engineer will assist the Engineering and Production Managers to drive improvement in OEE by focusing on micro/minor stops and breakdown reductions along with scrap reduction and other bakery productivity and innovation items. This role will work closely with the Controls Engineer role gathering key analytical insight in line performance and scrap results. The role will be located in a facility, however, have regional (4-6 bakery) responsibilities.


Principle Accountabilities are included but not limited to:


Through data analytics and insight look for key opportunities to improve OEE and production throughput.
Deliver scrap reduction projects and work closely with engineering/maintenance resource for optimum line performance.
Key contact for capital projects that drive productivity and increased line throughput
Work jointly with finance to understand plant financial metrics and insights into cost savings opportunities.
Must have the ability to lead technicians to assist in delivering efficiency gains, capital improvements and innovation.
Assists maintenance team on key equipment upgrades and routine maintenance requirements.
Helps train supervisors and hourly technicians on production line improvements and data analytic capabilities.
Assists in the installation, maintenance, and troubleshooting of Bakery Of the Future (BOF) systems as well as IoT/smart sensors and various other equipment that will be used with BOF. Will continue to work with the BOF teams, IT Department, Continuous Improvement Teams moving forward.


Desired Experience


Must have experience understanding production systems and optimizing throughput and scrap reduction
Good understanding of data extraction and analysis to gather key insights on improvement opportunities and cost reduction
Technical background and ease of learning production/batching equipment and systems.


Desired Education
Associates or bachelor’s degree in a technical field is a plus
The search for these positions will be nation wide to cover the footprint of our bakery locations. Flowers is willing to work with applicants in their preferred geographical areas. There will be some travel involved depending on current geographical areas


https://www.bimbobakeriesusa.com/press/2023-03-28/bimbo-bakeries-usa-earns-2023-energy-starr-partner-of-the-year-award-for-the-sixth


https://www.businesswire.com/news/home/20230802084217/en/Bimbo-Bakeries-USA-Minimizes-Waste-by-Improving-Its-Forecasts-by-30-with-Zebra-Technologies

2022

https://www.bakingbusiness.com/articles/56214-low-cost-production-remains-guiding-star-for-flowers










Tom Winters, new chief supply chain officer at Flowers Foods, Inc.


03.24.2022

Mr. Winters will be responsible for the company’s supply chain operations and will report to Bradley K. Alexander, chief operating officer. “Tom has more than 30 years of experience leading world-class teams and consistently delivering strong results and highly effective process improvements. We work to fuel business growth by implementing new digital capabilities and data management tools to improve core supply chain efficiencies throughout the company.”

Before joining Flowers, Mr. Winters was senior vice president of supply chain at PepsiCo, where he was responsible for the supply chain functions of two of the company’s North American divisions — beverages and nutrition. During his 19 years at PepsiCo, he also held a number of operations and production roles with responsibility for the management of internal plants, warehouses, and contract manufacturers. He began his career with Procter and Gamble, where he spent 15 years in operational leadership roles at production facilities in the continental United States and Puerto Rico.

Mr. Winters is a graduate of Virginia Tech with a bachelor’s degree in industrial engineering and also did  a management certificate course from the Kellogg School of Management at Northwestern University in Evanston, Ill.

https://tomlwinters.com/

https://www.foodbusinessnews.net/articles/20987-former-pepsico-exec-to-flowers-foods


2021


2021


FLOWERS FOODS: 40-YEAR OLD BAKERY CONVERSION PRIORITIZES ENERGY AND WATER PERFORMANCE

BACKGROUND

Flowers Foods operates 46 bakeries that produce a wide range of products for retail and foodservice customers. Its Lynchburg, Virginia, bakery has been in operation for more than 40 years. To meet the increasing demand for Dave’s Killer Bread (DKB) organic products in the Mid-Atlantic market, Flowers Foods converted Lynch bakery into a state-of-the-art, energy-efficient, sustainable bakery. The Flowers engineering team incorporated many energy and water efficiency technologies into the design of the Lynchburg bakery.  Based on five months of operational data, the production line upgrades are delivering an energy savings of 22.6% and water savings of 64.1%, and the company plans to implement many of the same technologies and practices at its other 46 manufacturing facilities and over 900 warehouses.


The company evaluates energy usage at the start of capital projects to ensure that new production lines not only improve productivity and quality but also deliver significant energy savings. As part of the Lynchburg project, Flowers Foods also took advantage of a performance-based grant through the State of Virginia and received $250,000 to cover the cost of the high-efficiency energy and water technologies installed in the plant.


SOLUTIONS

The Flowers engineering team incorporated many sustainability features into the bakery’s new design, including heat recovery, electric blowers in place of compressed air, a new variable frequency drive (VFD) air compressor for the trimming machine, LED lighting, recycling process improvements, and refrigeration upgrades. 808 lights were replaced with LEDs, and a high efficiency 150 hp VFD-equipped air compressor was installed to replace a less efficient 300 hp fixed speed model. The older chillers were replaced with new high-efficiency chillers and a waste heat recovery system was also implemented to increase energy efficiency and reduce process heating costs.

The heat recovery system is integrated internally into the plant’s catalytic oxidizer emission control system. Waste heat from the oxidizer is recovered to heat hot water for tanks, pipe and tank jackets, and ingredient water. The oxidizer recovery system can generate 0.75 MMBtu/hr. of energy at the source and includes an integrated coil and fin heat exchanger used to recover waste heat from the catalytic oxidizer exhaust. The installation includes custom programmable logic controllers (PLCs) and bypass dampers that regulate the exhaust flow rate through the coil heat exchanger, as well as the amount of heat applied to the coil. With the addition of the heat recovery system, two natural gas-fired boilers were able to be removed.

Other energy and water efficiency measures were integrated into the new cooling and refrigeration systems. These included refrigeration system controls that took advantage of variable flow control sequences using VFDs to reduce pumping system energy use. The new air-cooled chiller system uses significantly less water for cooling as well. In addition, new production processes were implemented to reduce water use. For example, the previous production line used a series of tanks that required regular cleaning. The new production line does not need these additional tanks and they were removed. Lastly, the recycling program was improved by installing a baler on location to improve storage and increase revenue from cardboard recycling. These energy-saving projects decreased the energy intensity by 22.6% from 5.2 MMBtu/ton to 4.0 MMBtu/ton in the first five months of operation. Water use decreased by 64.1% from 389.9 Gal/ton to 140 Gal/ton over this same period.

OTHER BENEFITS

The replacement of old lighting with new LEDs not only saved energy, but also improved lighting levels and reduced heat in the bakery. This improved working conditions in the bakery and reduced HVAC energy use. Due to the success of the energy saving measures implemented at Lynchburg, Flowers Foods’ engineering team will continue to incorporate similar technologies when planning facility upgrades and new production lines across its network. With 46 manufacturing facilities and over 900 warehouses, these best practices will make a significant impact on reducing energy consumption.


ANNUAL ENERGY USE

Baseline (2019)

5.2 MMBtu/ton

Actual (2020)

4 MMBtu/ton

ENERGY SAVINGS:

22.6%

ANNUAL ENERGY COST

Baseline (2019)

1

Actual (2020)

0.774

COST SAVINGS:

22.6%

https://betterbuildingssolutioncenter.energy.gov/showcase-projects/flowers-foods-40-year-old-bakery-conversion-prioritizes-energy-and-water




2020

https://flowersfoods.com/news/news-releases/2020/flowers-foods-announces-strategic-organizational-realignment-to-drive-brand-growth-and-product-innovation/



Industrial Standardization, Volumes 17-18

American Standards Association, 1947 - Standardization

https://books.google.co.in/books?id=lFzVAAAAMAAJ


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