How to review waste in a bakery

Separate the causes

Waste can mean ingredients lost during preparation, products damaged during production, unsold items or returned deliveries. Record these separately so that the figures point to a useful action.

Start with a small group of products. Use the same product names, units and recording method each day. Estimates are useful only when everyone understands how they were made.

Keep a short daily record

• Date, product and batch or shift.
• Quantity planned and quantity produced.
• Quantity sold or dispatched.
• Quantity returned, damaged or unsold, with a reason.
• The person recording the figure and any unusual event.

Review patterns before changing production

Compare similar trading days and note holidays, weather, promotions and large orders. A single slow day is not enough evidence to change a recipe or production plan.

Ask the people doing the work what happened. The answer may be inaccurate demand planning, handling damage, a recipe issue or a delivery problem. Each cause needs a different response.

Test one improvement

Choose one change, such as a smaller final batch or a different dispatch quantity. Keep a record of what changed and compare the result over a suitable period.

Software can help maintain consistent records, but it does not guarantee a reduction in waste. Any saving should be measured using your own figures and checked for changes in sales or product mix.

Decide when software will help

If the same figures are copied into several sheets, or the team cannot trace a product from ingredients to returns, review a connected workflow. Bring your existing recording sheet to a discussion, with confidential information removed.