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Fresher bread, no weekend overtime, and returns expected to be cut in half

Fresher bread, no weekend overtime, and returns expected to be cut in half

Koffee Kup Bakery

Food & Beverage

50%

expected cut in stale returns (conservative estimate)

10%

of sales lost to returns before

3 to 4 days

fresher bread

The problem

Koffee Kup's bakeries already ran 24/7 and still could not keep up in peak season. Bakers worked seven days a week for 12 to 16 weeks at a stretch, retention fell, and managers blamed turnover for poor quality. Stale returns climbed to 10% of sales in fiscal 2017.

What we did

  • Analyzed time cost, workload, workforce, absenteeism, turnover, routing, sales, and returns
  • Found most bread sells Thursday to Sunday, yet crews worked weekends to fill Monday shelves
  • Shifted production and delivery so 70% of product hits shelves Thursday and Friday
  • Implemented new schedules at two sites

The results

  • 50% expected cut in the return rate (conservative estimate)
  • 3 to 4 days fresher bread for customers
  • Hundreds of thousands of dollars in expected overtime and turnover savings (estimated)
  • No more overtime every weekend, with predictable schedules and more time off

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