Every bakery plant owner or plant head needs to monitor these top 10 figures to monitor production performance of the plant . Few companies depute independent factory cost control department with main objectives to tabulate these figures to management and to target improvement . If you can measures things then you can improve performance .
1 .Cost per unit ($/unit) -
Takes into consideration cost of all factors such as labour ,fuel, electricity , raw material , packaging and other miscl cost
2.Man-hours/unit
Number of labour employed per unit of product normally in tonnes or kg of product. Important cost factor in production cost of any factory
3. Units produced/unit time
total production done in unit time could be in kg/hr or tonnes/hr
4. Break down time (%)
Production stoppages due to machine or equipment failure against available running hours .
5.Change over time ( min/hrs )
Time taken for changeover of product from one sku to another. It requires change of moulders/cutters, recipes and packing machine settings. Changeover should be minimum as this results in loss of energy ,power and idle labour.The best option is to have dedicated lines with least changeovers
6.Waste (%)
Process generates waste in bakery operations and can be categorized as waste in mixing/premixing/forming /baking/packing /transportation
7. Defectives (%)
Defective are generated on equipment's such as oven and packing machines. Could be wet defectives or dry defectives need to be segregated and measured before recycling or discarding it in waste . Better to keep logs of defective at each equipment to monitor the largest source of defective generation
8.Fuel consumption ( litres of hsd/gas /unit)
Consumption of fuel to produce unit of product basically fuels consumed in ovens/ and power generation
9.Electricity consumption (kwh/unit)
It measures the amount of electricity consumed while producing bakery products . It includes power to run production machinery , utilities and admin block power consumptions . Thus few loads are variable but few are constant such as Utilities ( Compressors , Etp , Cold rooms, Chillers , Borewell. Lighting etc and admin )
10. Inventory turnover ( %)
Its measure the cost of goods sold over average cost of inventory held . A low inventory turnover can show that company has low sales hence large inventory where as higher value of Inventory turnover njumber would suggest faster sales and low inventory of finished good .
Normally most of the bakery companies have daily / weekly / monthly review of these figures
( data ) and steps to increase productivity and lower cost of production .
