Applying improvement tools for food industry: A case study at Wright (Part 2)

Based on good lean manufacturing practices, the Wright bakery continues to apply other innovative tools such as 5S, TPM, Lean and 6 Sigma. In particular, some managers during this time have received intensive training and received a 6 Sigma Yellow Belt certificate.

The 6 Sigma Yellow Belt is an effective management tool for manufacturers who are in the stage of scale expansion such as the Wright family. A 6 Sigma Yellow Belt employee is responsible for collecting the necessary data or data to report to a higher management level, and using his experience to solve problems of subordinates. In other words, 6 Sigma staff of the gold belt is a bridge to help the personnel apparatus can operate smoothly and effectively.

To solve the problem of wasting due to defective products, the improvement team proposed implementing a solution to empower employees. At each stage, the person in charge has the right to suspend production activities if they find a defect that causes the product to be of poor quality. This eliminates the need for a bakery to discard an entire shipment with a repeat error.

Besides 6 Sigma, 5S has also shown unexpected effectiveness with only minor changes. One of the basic principles of 5S is that items must be placed in an easy-to-find, easy-to-see, easy to get, easy to use position. This has been applied in bakeries with leather pouches next to each employee, greatly improving both quantity and product quality.

In the process of working, the baker is often distracted by some odd jobs such as taking tools, throwing garbage, dumping materials, etc. Small manipulations seem to have no effect. the process actually contributes to a significant reduction in labor efficiency. As an innovation expert, Bonds asserts: “The bakers are just like surgeons or pilots, needing high concentration. Working exclusively and seamlessly is an important factor in helping these employees improve their labor performance.”

In order to ensure the fulfillment of 5S criteria, the Wright family suspended production for one day just to clean, clean and rearrange the bakery. Machines and equipment are also checked, cleaned and maintained to prevent damage and improve efficiency. A neat, clean and safe workplace for health; an open working environment; A spirit of solidarity towards the common goal is what 5S brings.

By using and combining the right innovation tools, businesses can quickly achieve cost-effective results. The success at the Wright bakery is a testament to the efficiency of innovative tools that are not limited to large-scale, complex manufacturing processes.

Productivity and Quality Office