Baking&Snack - February 2012 - 48

HOSTESS BRANDS

The principle of the matter

One of the core principles guiding implementation of Lean Manufacturing at Hostess Brands, Irving, TX, is “Question everything, which takes strength from the fact that everyone has an opinion. “We are always ” asking, ‘Does it add value to the customer?’ This allows us to modify the process a lot, said Ron Wilson, ” field director, Hostess Brands. “Besides, it’s healthy to be able to question. ” For example, a shipping employee questioned the use of clear tape to seal cases of both chocolate and sugar donuts. He suggested that although products were clearly labeled by variety, different colors of tape would make the cases easier to select. Emporia changed to red and blue tape. “The result is that we no longer have the mix-ups in order picking that occurred before, Mr. Wilson noted. ” Another principle, “Promote information sharing, led the Emporia engineering department to develop a ” live scheduling system. Flat-screen monitors located throughout the bakery and in the maintenance shop display the production schedule. “We make more than 700 different SKUs here, and orders shift constantly, said Todd Crook, plant man” ager of the Emporia, KS, cake facility. “This often resulted in pieces of equipment being brought out to the floor but not used because production requirements had changed. ” Now, when the scheduler alters an order, the change shows up immediately on the monitors. Everyone from order processing through production, shipping and engineering can see what’s required. The company has since rolled out the system to many of its other bakeries.

“We presented 5S to the employees, and they took off with it. ”
Todd Crook, plant manager/general manager, Hostess Brands, Emporia, KS
mented through the corporate capital planning process, based on return on investment. The decision to pre-blend dry ingredients — a major change in how Hostess prepares its batters and doughs — embodies the 5S values of “Shine” and “Standardize.” “Most bakeries scale ingredients at the mixer,” Mr. Wilson explained. And like most bakeries, Emporia also batched small ingredients ahead of time, using 5-gal plastic buckets to hold these materials. “Even so, we still experienced some variations because of spillage and human error,” he said. Hostess engineers designed and installed an in-plant blending system to replace at-the-mixer scaling. The system’s ribbon blender mixes all dry ingredients for a given formula and discharges the mixture into 2,000-lb plastic tubs. Forklift operators move the tubs to a holding area and, as needed, place individual tubs on mobile dollies for transport to the use points. Blending takes place five days a week and produces to the order schedule. Each tub, which Emporia calls a module, is coded with the formula name, total weight and date of blending. Following the production schedule, mixer operators scoop out the required batch amounts and load them into the mixer. The ingredient system supplies liquids. Operators now work with one module per shift instead of 30 to 40 pails. “Quality went up, waste went down, and the consumer gets the same product every time,” Mr. Peele said. But there were even more important payoffs, which began to show up a few months after putting the blending system onstream. “With blending, costs went down, but consumer complaints went down

The bakery monitors its waste rate by recording the weight of damaged products collected at dump stations such as this one on the fruit pie line.
Blane Sutton

Adding up results
Four recent projects specifically demonstrate the benefits of 5S and Lean Manufacturing as practiced at Emporia. One altered mixing protocols, another optimized icing prep, the third improved waste reduction and the fourth reorganized distribution staging. “The mixing and icing prep projects involved small amounts of capital but had big impacts on operations,” Mr. Peele said. He noted that all capital projects were imple-

48

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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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