Baking&Snack - February 2012 - 46

HOSTESS BRANDS

pies to cool before they enter the Delta horizontal form/fill/seal wrapper that packages pies individually.

Stoking the engine
Each production line at Emporia depends on equipment customized for Hostess’ use, and each benefits from changes made through 5S. The process starts with teamwork applied not only to individual

By pumping cake icing directly from the prep system to the depositor, the bakery eliminated the extra handling and manual labor of previous methods.
Blane Sutton

departments but also to the plant as a whole. 5S provides an easy-to-understand framework. “5S means Sort, Set in Order, Shine, Standardize and Sustain,” Mr. Crook said. “And, of course, put into action.” (See “Five S’s, plus a sixth” on Page 52.) “We presented 5S to the employees, and they took off with it,” he added. “Sort” eliminates clutter. If a piece of equipment or a tool hasn’t been used in a week, any employee can stick a red tag on it. The object is then moved out of the production plant and away from daily activities. “Early on, we red-tagged and took out a good five or six truckloads of extraneous stuff,” Mr. Wilson said. “Set in Order,” Mr. Peele explained, “basically means a place for everything and everything in its place. It’s a time management approach that makes sure tools and equipment are where they should be. Just the placement of a utensil at a different location can make the difference between one unit of waste versus 10 units.” The bakery established fixed spaces for every tool, utensil and moveable piece of equipment. In some

BRC protocols, too

Almost three years ago, Hostess Brands, Irving, TX, adopted British Retail Consortium (BRC) Global Standards for certification of food safety companywide. The Emporia, KS, cake bakery achieved an “A” rating in its latest inspection, its second under these protocols. “BRC affects the entire bakery, including how we track and document activities, said Plant Manager Todd Crook. ” Ongoing training is a BRC pillar, requiring annual updates for all staff with testing done throughout the year. “Every employee gets training, with leaders getting more, Mr. Crook said. The company takes a train” the-trainer approach, providing instruction first to supervisors, who then train their teams. “Also, under BRC, you have to verify that the training is done, ob” served Ron Wilson, field director, Hostess Brands. For more technical bakery-specific education, Hostess Brands sends staff to American Institute of Baking resident courses and seminars. It also offers its own classes in manufacturing, function of ingredients, control of downtime and so forth. Cake classes take place at the Emporia bakery in periodic 2-week sessions.

cases, yellow paint delineates the storage space; in others, the bakery installed hard yellow-colored pieces of plastic and numbered metal plates directly into the tile floor. Thus, operators always know where to find a given item. “Shine” stipulates that all staff members are tasked with cleaning their work areas when they finish their work and shifts. It also prioritizes waste management, preventing spillage, reducing cripples, cutting wastewater and recycling materials. “Standards” led to development of the “blue boards” found throughout the bakery. These display photos of acceptable and unacceptable products. They also show results, listed by department and for the plant as a whole. Mr. Wilson explained the guiding principles of the company’s business practices as “teamwork; be the best at what you do; question everything; creativity before capital; develop a knowledge base; and promote information sharing.” “Teamwork is essential, and we also keep score,” Mr. Crook said. “We want our employees to feel good about what they do, and thus, scoring has to be objective.” He meets every Tuesday morning with the bakery’s supervisors, reviewing the goals, standards and results for each department. Supervisors read their departments’ numbers in front of their peers. Results are also calculated as an overall number representing the plant as a whole. The numbers are posted in the conference room and throughout the bakery. This tactic fosters the sense of individual responsibility that is an essential component of 5S. “If someone misses his or her number, it’s our job as a group to focus the effort to hit the desired result,” Mr. Wilson explained. “It’s about the quality of the product, the quality of our work.”

46

/ Baking & Snack / February 2012

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Baking&Snack - February 2012

Table of Contents for the Digital Edition of Baking&Snack - February 2012

Baking&Snack - February 2012
Table of Contents
Table of Contents
Editorial - Fresh start to 2012
Newsfront - Canada Bread sets ambitious goals in 2012
Newsfront - Hostess Brands files for bankruptcy again
In Brief
News - ASB selects four to 2012 Hall of Fame
News - Kraft to reduce workforce as part of realignment
News - GMA director to lead new food safety alliance
In Brief
News - Whole Grains Summit aims at whole world
News - FTRAC convenes with ARS in Boston
In Brief
Correction and Clarification
People
In Memoriam
Right on Track
Back on Track
Industry Insight - Managing Valued Assets
Going Lean, Cutting Waste
Breakfast Trends - Keeping Breakfast in Balance
Botanicals - Extracts with Benefits
Probiotics - Working with Probiotics
Ingredient App - Vanilla Upgraded
Regulatory Q&A - Better Safe than Sorry
Oven Technology - Ability with Agility
Pan Management - Automating Pan Handling
In Recovery Mode
From Pan to Hearth
Food Safety Q&A
ABA FTRAC Q&A
Course Preview - Getting Ahead of the Learning Curve
Events
Innovations
Ingredient News
Products & Packaging
Patents
New on the Shelf
Marketplace
Ad Index
New Product Spotlight - Superfruits to the Rescue
Baking&Snack - February 2012 - Baking&Snack - February 2012
Baking&Snack - February 2012 - 2
Baking&Snack - February 2012 - 3
Baking&Snack - February 2012 - 4
Baking&Snack - February 2012 - 5
Baking&Snack - February 2012 - 6
Baking&Snack - February 2012 - 7
Baking&Snack - February 2012 - 8
Baking&Snack - February 2012 - Table of Contents
Baking&Snack - February 2012 - 10
Baking&Snack - February 2012 - Table of Contents
Baking&Snack - February 2012 - Editorial - Fresh start to 2012
Baking&Snack - February 2012 - 13
Baking&Snack - February 2012 - 14
Baking&Snack - February 2012 - 15
Baking&Snack - February 2012 - Newsfront - Canada Bread sets ambitious goals in 2012
Baking&Snack - February 2012 - In Brief
Baking&Snack - February 2012 - News - ASB selects four to 2012 Hall of Fame
Baking&Snack - February 2012 - 19
Baking&Snack - February 2012 - In Brief
Baking&Snack - February 2012 - 21
Baking&Snack - February 2012 - Correction and Clarification
Baking&Snack - February 2012 - In Memoriam
Baking&Snack - February 2012 - Right on Track
Baking&Snack - February 2012 - 25
Baking&Snack - February 2012 - 26
Baking&Snack - February 2012 - 27
Baking&Snack - February 2012 - 28
Baking&Snack - February 2012 - 29
Baking&Snack - February 2012 - 30
Baking&Snack - February 2012 - 31
Baking&Snack - February 2012 - 32
Baking&Snack - February 2012 - 33
Baking&Snack - February 2012 - Back on Track
Baking&Snack - February 2012 - 35
Baking&Snack - February 2012 - 36
Baking&Snack - February 2012 - 37
Baking&Snack - February 2012 - 38
Baking&Snack - February 2012 - 39
Baking&Snack - February 2012 - 40
Baking&Snack - February 2012 - 41
Baking&Snack - February 2012 - 42
Baking&Snack - February 2012 - Industry Insight - Managing Valued Assets
Baking&Snack - February 2012 - Going Lean, Cutting Waste
Baking&Snack - February 2012 - 45
Baking&Snack - February 2012 - 46
Baking&Snack - February 2012 - 47
Baking&Snack - February 2012 - 48
Baking&Snack - February 2012 - 49
Baking&Snack - February 2012 - 50
Baking&Snack - February 2012 - 51
Baking&Snack - February 2012 - 52
Baking&Snack - February 2012 - 53
Baking&Snack - February 2012 - 54
Baking&Snack - February 2012 - Breakfast Trends - Keeping Breakfast in Balance
Baking&Snack - February 2012 - 56
Baking&Snack - February 2012 - 57
Baking&Snack - February 2012 - 58
Baking&Snack - February 2012 - 59
Baking&Snack - February 2012 - 60
Baking&Snack - February 2012 - 61
Baking&Snack - February 2012 - 62
Baking&Snack - February 2012 - 63
Baking&Snack - February 2012 - 64
Baking&Snack - February 2012 - Botanicals - Extracts with Benefits
Baking&Snack - February 2012 - 66
Baking&Snack - February 2012 - 67
Baking&Snack - February 2012 - 68
Baking&Snack - February 2012 - 69
Baking&Snack - February 2012 - 70
Baking&Snack - February 2012 - Probiotics - Working with Probiotics
Baking&Snack - February 2012 - 72
Baking&Snack - February 2012 - 73
Baking&Snack - February 2012 - 74
Baking&Snack - February 2012 - 75
Baking&Snack - February 2012 - 76
Baking&Snack - February 2012 - 77
Baking&Snack - February 2012 - 78
Baking&Snack - February 2012 - 79
Baking&Snack - February 2012 - Ingredient App - Vanilla Upgraded
Baking&Snack - February 2012 - 81
Baking&Snack - February 2012 - 82
Baking&Snack - February 2012 - Regulatory Q&A - Better Safe than Sorry
Baking&Snack - February 2012 - 84
Baking&Snack - February 2012 - 85
Baking&Snack - February 2012 - 86
Baking&Snack - February 2012 - Oven Technology - Ability with Agility
Baking&Snack - February 2012 - 88
Baking&Snack - February 2012 - 89
Baking&Snack - February 2012 - 90
Baking&Snack - February 2012 - 91
Baking&Snack - February 2012 - 92
Baking&Snack - February 2012 - 93
Baking&Snack - February 2012 - 94
Baking&Snack - February 2012 - 95
Baking&Snack - February 2012 - 96
Baking&Snack - February 2012 - Pan Management - Automating Pan Handling
Baking&Snack - February 2012 - 98
Baking&Snack - February 2012 - 99
Baking&Snack - February 2012 - 100
Baking&Snack - February 2012 - 101
Baking&Snack - February 2012 - 102
Baking&Snack - February 2012 - 103
Baking&Snack - February 2012 - In Recovery Mode
Baking&Snack - February 2012 - 105
Baking&Snack - February 2012 - 106
Baking&Snack - February 2012 - 107
Baking&Snack - February 2012 - 108
Baking&Snack - February 2012 - 109
Baking&Snack - February 2012 - From Pan to Hearth
Baking&Snack - February 2012 - 111
Baking&Snack - February 2012 - 112
Baking&Snack - February 2012 - Food Safety Q&A
Baking&Snack - February 2012 - 114
Baking&Snack - February 2012 - 115
Baking&Snack - February 2012 - 116
Baking&Snack - February 2012 - ABA FTRAC Q&A
Baking&Snack - February 2012 - 118
Baking&Snack - February 2012 - 119
Baking&Snack - February 2012 - 120
Baking&Snack - February 2012 - Course Preview - Getting Ahead of the Learning Curve
Baking&Snack - February 2012 - 122
Baking&Snack - February 2012 - Events
Baking&Snack - February 2012 - Innovations
Baking&Snack - February 2012 - Ingredient News
Baking&Snack - February 2012 - 126
Baking&Snack - February 2012 - Products & Packaging
Baking&Snack - February 2012 - 128
Baking&Snack - February 2012 - 129
Baking&Snack - February 2012 - 130
Baking&Snack - February 2012 - 131
Baking&Snack - February 2012 - Patents
Baking&Snack - February 2012 - 133
Baking&Snack - February 2012 - 134
Baking&Snack - February 2012 - New on the Shelf
Baking&Snack - February 2012 - 136
Baking&Snack - February 2012 - 137
Baking&Snack - February 2012 - 138
Baking&Snack - February 2012 - Marketplace
Baking&Snack - February 2012 - 140
Baking&Snack - February 2012 - 141
Baking&Snack - February 2012 - 142
Baking&Snack - February 2012 - 143
Baking&Snack - February 2012 - 144
Baking&Snack - February 2012 - Ad Index
Baking&Snack - February 2012 - New Product Spotlight - Superfruits to the Rescue
Baking&Snack - February 2012 - 147
Baking&Snack - February 2012 - 148
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