UK bakery needed to improve efficiency and profitability

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The company

We worked with the largest bakery brand in the UK.  They do not rest on their laurels and are pioneers of the industry and ambitious market leaders, always seeking to challenge themselves and convention.

Their needs

The bakery in question required an assessment of their current losses to establish areas of focus for improvement opportunities and recommended approaches.

How we helped

Following a lean assessment a Total Productive Maintenance programme was rolled out with focus on improving maintenance resource and organisation. Alongside we provided production operators with training in Lean and basic Problem Solving techniques. The initiation of good housekeeping in and around the production facility set the foundations for continuous improvement. A simple management tool was also developed to track both opportunities and improvements.


Not only were the efficiency losses reduced by half, wasted dough and bakery damage also reduced. Some specific Improvements were:-

  • Reduced slicer change over times
  • Reduced equipment repair time
  • Improved functionality in the engineering department avoiding sub-contracting work
  • Reduced production downtime


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