FactoryEye Enables Angel Bakeries to Accurately Calculate Production Quantities & Move from Manual Labor to Automation

BACKGROUND

Founded in 1927, Angel Bakeries is publicly traded on the Tel Aviv stock exchange. Today, it has 4 industrial bakeries around Israel, 20 local bakeries, 150 distribution lines across Israel, and is an approved supplier for some of the world’s leading fast-food chains, including McDonalds and Domino’s Pizza. The bakery also exports its products around the world and produces frozen goods in its US plant for distribution across the USA. 

CHALLENGE

As fresh products, bakery and bread products cannot be stored. To prevent superfluous production, Angel Bakeries sought a solution to accurately calculate production quantities and obtain inventory reports in real time. The bakery also wanted better control of work performed on their production lines, including reporting of stoppages or failures, in order to improve line usage and facilitate more precise planning.

SOLUTION

Magic Software’s FactoryEye was selected because it provides an advanced, easy-to-use machine connection, data visibility, and a smart IoT solution for production. Empowering Angel Bakeries to computerize the process of control and reporting in production, it uses RFID stickers that are automatically scanned and used to update data in the computer systems. This has significantly reduced the time spent on manual reporting, as well as solving the problem of inaccuracies. At two production sites, automatic gates that are opened by reading the stickers have been installed, thus reducing human involvement in reporting to a minimum.

Before FactoryEye, Angel Bakeries production personnel were dependent on manually-produced reports, which generated problems, shortages and inaccuracies. Now they can guarantee the availability of stock for distribution during the night, when the delivery trucks set out, or when the products are transferred to a temporary warehouse on the way to loading. And at the start of delivery rounds each day, the contents of each delivery truck are identical to the contents listed in system records, making inventory control and internal processes far more efficient.

In addition to transparency regarding inventory at any point in time and the smooth flow of information, FactoryEye also offers better monitoring of deliveries in the supply chain, as well as making it easier to investigate incidents and improve forward planning.

RESULTS

• Smarter and faster responses with real-time data.
• Reduction in the time spent on manual reporting.
• Upgrading of the control process to increase accuracy in production quantities and reporting.
• Better control over delivery times and inventory management.
• Improved efficiency, accuracy, reliability and productivity. 
• Plans to use FactoryEye to improve efficiency in other production processes and the flow of information, such as online control of production lines, handling gaps and production losses, and analyzing the causes of stoppages and the resultant losses in production time.