CASE STUDY: Bakkerij Bouman

Bakkerij Bouman’s challenge/problem

"Is the production line capable of producing reliably in the coming years, or do we have to convert or perhaps even renew it?"

Bakkerij Bouman approached UNIS Group with the following starting point: "We want to continue with the current production line for at least another 5 years, but we do not want the production line to come to an unexpected (long-term) grinding halt. We just can't afford that."

It is essential in the (fresh) food sector that a production line produces without unplanned downtime. For a daily fresh bakery like Bakkerij Bouman, a production stop of (more than) 3 hours is just not an option.

In such a situation, planning ahead is extremely important: "Is the production line capable of producing reliably in the coming years, or do we have to convert or perhaps even renew it?"

Converting, or continuing with the current control system?

For Bakkerij Bouman, at least one thing was clear: For the next 5 years, the focus must be to extend the life of the current production line. The purchase of a new production line is not yet on the agenda. That’s why the question remained whether it is possible to continue running with the current production line in the coming years, or whether the production line must be (partially) converted.

The machine builder’s advice focussed on replacing control cabinets and fitting new components in the production line. However, this bodes a very big disadvantage for Bakkerij Bouman:

“Converting the production line takes time and entails a production stop of at least a week. A week in which no bread can be baked."

Looking for a more suitable option, Bakkerij Bouman contacted UNIS Group. We were asked to check what kind of modules are present in the control cabinets, and to indicate which parts are still available or replaceable.

Our solution: 'Taking stock, evaluate and facilitate critical items'

Bakkerij Bouman’s request ties in perfectly with our 'Stocktaking and evaluation' service. On site, one of our Field Service Engineers took stock of the electronics present in the control cabinets to provide insight into the (worldwide) availability of the electronics in these cabinets.

Stocktaking

One of our Field Service Engineers has taken stock of the electronics present in the control cabinets of the production line on site. We also took a picture of each module, to ensure both UNIS and Bakkerij Bouman can carry out an accuracy check on the modules’ data afterwards. In addition, in the event of any ambiguity, the correct information can always be retrieved.

After our visit to Bakkerij Bouman's bakery in Geldermalsen, we mapped out the following:

• The (worldwide) availability and supply of the electronics, both new and refurbished.
• The electronics for which UNIS Group offers a service.
• Which electronics can be repaired.

A quotation for stocking critical modules

Modules that are difficult to deliver or that cannot be repaired often turn out to be critical modules. These parts can potentially cause (long-term) downtime of the production lines if they become defective.

Downtime that Bakkerij Bouman cannot afford, as mentioned earlier. That’s why, at Bakkerij Bouman's request, UNIS Group immediately drew up a quotation for the supply of the necessary (critical) modules. The quote was used to compare the costs of converting the production line.

The result: Less uncertainty, no maintenance stop and substantial cost savings

In the end, the Bakkerij Bouman TD assessed all the scenarios, and opted to continue running with the current production line, without converting it. However, they decided to proactively replace (critical) modules in the production line in order to minimize the chance of downtime. With a view to the future, it has also been decided to invest in new stocks, both for critical modules and additional essential modules.

At Bakkerij Bouman’s request, we searched our extensive network of suppliers for the critical parts, and overhauled them. In a period of about 6 months, we ensured Bakkerij Bouman had all critical parts tested and therefore in good condition on the shelf in the warehouse of the production site in Geldermalsen.

Stockpiling ~60% cheaper than converting the production line

In total, UNIS Group’s stocktaking and the purchase of new (spare) stock was about 60% cheaper than having the production line converted. And thanks to the new knowledge and accumulated stock, Bakkerij Bouman can continue running the required 5 years with the current production line.