Page 58 - QUALITY Magazine (Volume 03 - Issue I)

03. In your experience, how do you ensure directly impacts productivity and costs. As manual
03.
consistency in product quality while operations dominate, the bakery sector struggles
maintaining operational efficiency in a to keep up with rising production costs. A key
baking production environment? reason for this is the scarcity of skilled labor. Skilled

To me, maintaining consistency comes down to operators, who are critical for handling manual
mastering the basics. Operational excellence is about processes, are increasingly seeking opportunities
simplifying processes so that they are clear and abroad, particularly in the hospitality industry.
actionable for the people handling them. In my work, Their experience opens doors to better-paying
we deal with perishable products and live organisms jobs, leaving local bakeries struggling to fill these
like yeast, which are integral to the fermentation positions. To counter this, automation is essential.
process. Yeast, being a live entity, requires precise By adopting modern, automated processes, the
handling to achieve the desired volume, flavor, and industry can reduce its reliance on manual labor,
quality in the final product. Consistency demands lower production costs, and increase efficiency. If
excellence in fundamental practices, such as this transition does not happen, the industry risks
maintaining the right dough and oven temperatures, significant disruption or even collapse within the
as well as ensuring proper cooling processes. This next decade. Automation is not just an option; it’s
is where operational excellence becomes crucial by pivotal for the long-term sustainability and growth
establishing standards, norms, and a framework for of Sri Lanka’s bakery industry.
continuous monitoring.

For example, we ensure oven temperatures are
checked every hour, dough temperatures are verified
at the start of the process, and the fermentation
process is carefully timed, typically 40 to 45
minutes, before moving to the next step. By setting
clear timelines, process controls, and monitoring
protocols, we create a system that is both efficient
and reliable. This approach not only ensures product
consistency but also supports faster, more efficient
operations, which is the essence of operational
excellence.

04. What is your opinion on the integration
04.
of new technologies and automation
in the baking process to enhance

efficiency?
The Sri Lankan bakery industry faces several
significant challenges that stem from both
technological and workforce-related issues. While “Operational excellence
we are the producers of the second-largest staple
food in the country (bread) and our industry is the backbone of our ability to
remains largely dependent on outdated and stay competitive and meet the
primitive technology. Most bakeries use basic ovens diverse demands of the
and mixing machines, which require substantial Sri Lankan bakery market”
manual involvement, unlike the highly automated
systems in other countries. This lack of automation