Baking & Snack - March 2016 - 27

When installing new equipment, many companies now
strive for a vertical startup, which means meeting key
objectives for any project during the first days of starting
up production - or roughly translated, doing it right the
first time. For Campbell Soup, parent of Pepperidge Farm,
that means hitting 80% of overall equipment effectiveness
on Day One. "For a vertical startup, you have to have high
confidence when that equipment hits the floor that you
can achieve a very quick ramp-up," Mr. Watson said.
For training during a vertical startup, Campbell
employs a three-part process called CQV, or commissioning, qualification and verification. "In each one of
those phases, there's a certain amount of training that
the hourly workforce is responsible for versus the vendor," Mr. Watson explained. "By the time you get to the
qualification phase and the sign-off on the equipment,
the vendors are standing back and watching the operators run the equipment. They're only there to answer a
question. When the final phase - verification - is implemented, the operators are running the line with no
intervention from the vendors.
"Too many times in the past, the vendors would come
in, and they'd be running the equipment [throughout
commissioning]," he continued. "Then you sign off on
the equipment, and now the workforce is stumbling as
they try to operate the equipment on their own. Then
you have to bring the vendors back two or three times.
Now we're trying to get to the place where when the vendors leave, they don't come back. The training is done.
Everything is signed off. Unless there is a major failure
during the warranty period, we don't expect them back."

Talking tech and training
Training has emerged as a critical issue as bakeries incorporate sophisticated process controls as well as more
complex technologies. For instance, many bakers and
snack producers have integrated the latest generation of
robotics into packaging, warehousing and other areas
throughout the process. In fact, 44% of those bakers who
plan to attend IBIE 2016 are exploring the possibility
of purchasing robotics this year, according to Baking &
Snack's exclusive survey on capital spending and equipment trends, published in February. Nearly one-third
(31%) are looking at robotic automation for packaging.
Although bakeries have been using robotics since the
1980s, such systems have made quantum leaps in their
dexterity, their vision systems and the user's ability to
program them more easily. "There are a lot of 3D vision
systems out there that not only locate the product but also
measure the depth of that product to be better able to improve the tray-packing or cookie-cupping processes," Mr.
Watson noted. "Robotics today are more user-friendly
and have higher speeds, and the cost has come down dra-

ABA tackles the 'workforce gap'
As technology has advanced, so has the difficulty of hiring qualified, skilled employees. "As systems get more
complex, the challenge becomes the maintenance and
operations side of the business, and how you can support
that technology to keep it up and running," noted Dave
Watson, vice-president of engineering, global biscuits and
snacks, Campbell Soup Co. "Finding good technical people
is tough, and it's getting tougher. The younger generation
doesn't necessarily want to work in a bakery. They don't
want to be working on a Sunday evening when it's time for
start-up and deal with the crazy hours of bakeries."
The American Bakers Association (ABA) is addressing
this pressing issue in one of its IBIE education sessions
called, "The Workforce Gap in the US Commercial Baking
Industry: Trends, Challenges and Solutions." According to
ABA, the project will provide proactive solutions to help
the baking industry compete with other business sectors
for talent.
The growing skills gap within US manufacturing and
specifically within the baking industry, is a major concern
for the ABA Human Resources Committee, according to
Laurie Graves, director, people systems, The Bama Co.
and ABA HR Committee chair. "We've been laser-focused
on identifying solutions to help attract and retain talent
and will continue to do so," she said. "The good news is
that with ABA's leadership, the baking industry is united in
resolving this crisis, and we look forward to showcasing
many of the unique solutions we've identified at IBIE."
Overall, ABA is presenting seven educational seminars
at IBIE 2016 that explore such topics as future consumer
trends for baked goods, developing the next generation
of industry leaders, and key government affairs issues
- such as an analysis of food safety regulations and the
upcoming election - and how they can affect companies'
bottom lines. Additionally, ABA baker members will present case studies on alternative energy fuels for shipping as
well as the successes and challenges involved in completing the US EPA's Energy Star challenge.
Other associations such as BEMA, Retail Bakers of
America, AIB International and the American Society of
Baking are providing a variety of educational forums.
"People are buying equipment at the show, but they
want to know where else they need to invest their money
- whether it be in compliance for new regulations or to
pay for new taxes or additional costs that might ultimately
affect their purchasing decisions," noted Lee Sanders, ABA
senior vice-president, government relations and public
affairs. "What ABA is offering will nicely complement the
overall IBIE experience beyond the show floor with all the
new technology and new equipment."

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Baking & Snack - March 2016

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