Bread manufacturers face common challenges when it comes to wastage, with losses occurring at every stage, from dough preparation to packaging. Identifying the root causes of these losses—when, where, and why they happen—has always been difficult, with traditional methods falling short.
Visual AI presents a next generation solution by using existing CCTV systems to provide real-time insights that go beyond what traditional tools offer. Here’s how Visual AI can help bakeries reduce bread wastage and improve production efficiency.
1. Real-time OEE: Improved visibility across the bread line
Tracking dough and loaf movement
Visual AI allows manufacturers to monitor key stages of the production process, from counting dough pieces as they exit the divider to tracking loaves as they are depanned, cooled, and packaged. This gives a clear, real-time view of production performance, identifying areas where losses such as dough misplacement or packaging errors occur most frequently.
Monitoring line availability and downtime
Visual AI tracks machine availability, detecting when mixers, ovens, or packaging lines stop, and providing insights into both long and short stops. Short stops, like conveyor jams, often go unnoticed but can significantly impact overall efficiency. By addressing both types of stoppages, bakeries can improve uptime and reduce wastage.
Automating quality control checks
Visual AI also automates key quality control checks, such as ensuring dough is correctly placed in pans and lids are properly applied. This automation reduces human error, prevents unnecessary waste, and ensures more consistent product quality.
2. Pinpointing losses with visual evidence
Loss categorization is an ongoing challenge for bread manufacturers due to unreliable manual data entry and difficulty in identifying the root causes of wastage. Visual AI addresses this by capturing a visual audit log of key production events, making it easier to pinpoint the reasons for downtime and losses.
For example, when dough is mishandled or depanning errors occur, Visual AI records these incidents in real time, providing both data and visual evidence. This enables accurate categorization of losses and highlights recurring issues, helping bakery managers implement targeted solutions.
By automating the capture of visually distinct reasons for losses, Visual AI reduces the need for manual logging, improves data accuracy, and simplifies trend identification over time.
3. Turning data into actionable insights
Visual AI generates actionable insights from the data it collects, allowing bakery managers to proactively address issues. For example, recurring short stops or dough misalignment can be flagged, helping managers take immediate action before problems escalate. This shift from reactive to proactive management helps bakeries become more data-driven, reducing wastage and optimizing production.
About visionAI
visionAI is a leading visual AI software company that helps bread manufacturers reduce wastage and increase efficiency by transforming existing factory cameras into powerful tools for real-time OEE monitoring and loss analysis. visionAI’s OEE+ for Bakeries unlocks the potential to leverage visual AI to reduce waste, run smoother operations, and boost profitability.
