Baking

The commercial baking industry is unique in that it ranges from huge and very recognizable global brands to much smaller but still very successful local operations. Whether you are a regional subsidiary or a small private bakery, you are likely to face a similar set of challenges. With persistent supply chain shortages, increasing labor costs, and trends toward more health-conscious alternatives, many bakeries have pivoted their strategy to either invest in new equipment that can more easily produce goods that follow new consumer trends or to focus on adapting current equipment to meet those needs. At the same time, many commercial bakers have had to pivot to support new online distribution channels as well as supplying local or retail channels.

Investment in new capital equipment and upgrades to existing lines necessitate new production rates and standards. Bakeries equipped with automated production monitoring and OEE equipment like Vorne XL are able to immediately recognize and analyze these changes, adjust baselines, and set new standards, enabling them to focus on their ultimate goal of servicing the client… efficiently and effectively. They are also well-positioned to help operators by providing them with real-time plant floor feedback through visually impactful scoreboards. Vorne XL moves baking operations far beyond manual data capture to gain critical insights for effectively driving process improvement and actualizing change with 100+ metrics and 20+ data dimensions.

Other benefits of XL that customers love include no software to install, no servers to maintain, no recurring fees, and no contracts. Instead, you get unlimited users, free technical support, a 3-year warranty, and free software updates - all in an inexpensive, off-the-shelf product.

Driving Improvement for Baking

Our baking customers strive to make something that tastes nostalgic (or new and trendy), is health-conscious, and is more affordable and accessible than other options on the market. It is critical to be able to optimize the process while maintaining the product that their customers love.

The Vorne XL Productivity Appliance empowers baking manufacturers to monitor their processes, improve throughput, and maximize efficiency, all while preserving the integrity of their products. XL drops onto your existing process, making it a quick and easy solution that requires little to no changes on the line.

Key Benefits for the Baked Goods Industry

Vorne XL products are completely agnostic to the type of equipment in your manufacturing process. This is a huge advantage as you can easily apply XL to any line and get the same wealth of information. XL includes I/O to integrate with your process, a scoreboard for your operators, and built-in reporting for your managers. It scales from machine to enterprise. Monitor your depositors or dividers, ovens, mixers, freezers, cartoners or boxers, and other equipment with one solution, quickly seeing benefits such as:

Reduce Changeover Time Allergen washes are common in the baking industry. Precisely monitor your changeover process and times and encourage your operators to maintain or improve their average changeover times.
Visible Downtime Tracking In many instances, a full baking line may be split between walls or rooms, limiting communication between operators. Having multiple, real-time displays emphasizing when the process has stopped and for what reason is critical to align operators so they can react appropriately.
Speed and Rate Metrics Baking lines may deploy multi-head depositors or dividers, supplying multiple lanes with product. See the impact on performance if a lane goes down in real time as you monitor speed and rate in PPM or PPH.
Historical Production Data and Comments Baking lines deal with variable products that can be influenced by a myriad of external factors when running. The ability to record years of product-specific data along with operator comments is critical to analyzing exceptions in the process and mitigating those exceptions moving forward.
Automated Alerts Having the next batch of ingredients ready for the line is important for reducing downtime. Set up automated email or text message alerts to notify you when a line is close to completing a changeover, ensuring minimal downtime between batches.

Metrics, Dimensions, and Dashboards

Vorne XL delivers an incredible data foundation and the tools you need to effectively drive your continuous improvement, lean manufacturing, and digital transformation initiatives. With XL you get immediate access to over 100 highly accurate and actionable metrics and 20 data dimensions - in real time and for deep retrospective analysis through historical reporting. There are dozens of built-in reports, and you can easily create your own reporting dashboards.

15%

Downtime Reduction

L.C. | Manufacturing Engineer | Global Auto Parts SupplierTwo years ago we brought in the Vorne XLs as part of our lean program. We wanted to measure and improve efficiency on seven lines. OEE gave us a reliable way to measure our progress and also a tool for identifying areas where we can improve. Over this time we have increased our OEE by an average of 20 points and our downtime is down by 15 to 20%. Vorne has been with us every step of the way. We are proud that we have improved and also that we are maintaining our gains. Vorne has been a trusted partner in our journey, providing us the tools and support to help us improve our productivity.

2 Days

ROI

F.S. | Controls Engineer | Fortune 500 Food ProducerVorne XL pays for itself in 2 days! Yesterday was the first time we looked at the results since installing XL. The direct result of the display was amazing. We went from running at $9,000 below target per month to a new gain of nearly $30,000 a month!

Years Trusting Vorne

J.D. | Maintenance Manager | Food Products ManufacturerI have purchased and installed Vorne products for almost 10 years now, so I trust their ability to survive in a food manufacturing environment. The XL Series allowed me to introduce a new concept – real-time visualization – for very little cost and complexity. The alternative would have been to use PLCs, interface them with a PC, find and run software on the PC to drive the displays, and interface them with the displays. There is simply no comparison! I really like the product and will recommend it wholeheartedly to anyone.

146%

OEE Improvement

W.M. | Operations Manager | Food Manufacturing PlantI've used Vorne XL in my last three roles and it has really made a difference. When I joined my last plant our OEE was 30%. Each month we picked a focus metric from the XL and trained the team on that metric. I showed everyone how it affected the line and then we worked together to drive up the number. We steadily improved, and when I left the plant our OEE was 74%!

30%

Labor Savings, 31 Day Payback

G.K. | Continuous Improvement Manager | Global Food Service ProviderWe purchased a Vorne XL display to help us monitor production rates and apply lean manufacturing tools to one of our many value streams. By efficiently working to takt time, we have been able to eliminate waste and improve productivity, while maintaining our commitment to quality. We have calculated a 30 percent labor savings on our pilot project which yielded a 31 day payback. Since the pilot we have installed another two XL displays. As you can imagine, we will be continuing to add more Vorne displays!

OEE Improvement In First Month

R.N. | Continuous Improvement Manager | Food Ingredients ManufacturerWe bought an XL system in September, and within a month we were seeing improvements of up to 8% in our OEE. Our OEE is now trending towards a 10% improvement. After our first month we visited Vorne for a 2 day training session and have left with a really solid plan to maximize how we use the system. We have now started introducing XL to our sister plants to align it with our group OEE methodology.

Best Investment of the Year

T.G. | Plant Manager | Specialty Food Products ManufacturerWhen I saw XL I told our General Manager that this is the single most important investment we will make this year. Just the other day our CEO was walking through the plant. When he glanced at the production display, his jaw dropped. He was surprised to see over two hours of downtime. Without the display, it would likely be a whole lot more and we wouldn't find out until the next day when it is too late to fix it. XL really helps us put a spotlight on the dark areas and expose our productivity losses. XL is the secret ingredient for high efficiency!

92.8%

Trial Conversion Rate

M.R. | Process Manager | Specialty Food ManufacturerVorne is one of the best purchases I have made this year. I've spent millions on production equipment and although XL was a much lower investment, it has proven to be the most successful for the entire plant. Any questions I’ve had so far, Vorne’s already had an answer.

Must Have

For Production Environments

Phillip M. | Senior Technician | Food ProductionEasy onboarding. Reliable metrics. Fantastic support. Informative training.

Year 1

Vorne XL Experience

Mario T. | Data Analyst | Food and BeverageXL is extremely user friendly to navigate through the system and look at data, create reports, and adjust settings. Easy installation of the XL upgrade with easy to follow manuals and guides. Configuration of one device is easy and once you have it done for one device you can simply download and upload that configuration onto other devices with similar configuration settings. The staff at Vorne is also extremely knowledgable and always willing to help you get the best experience out of the Vorne XL platform.

15%

Downtime Reduction

2 Days

ROI

Baking

Driving Improvement for Baking

Key Benefits for the Baked Goods Industry

You're In Excellent Company

Learn More About Vorne XL

Metrics, Dimensions, and Dashboards

Vorne XL User Success Stories

Baking Specialties