Achieving operational excellence in a growing bakery group

For over 85 years, one of Belgium’s most renowned bakery groups has been delighting customers with artisanal bread, pastries, and confections. What started as a single location near Ghent has grown into a thriving chain with multiple stores across the country, many of which feature cozy tearooms where patrons can enjoy a wide array of freshly baked goods. The company remains deeply rooted in craftsmanship and tradition while embracing innovation to enhance its customer experience.

How a Belgian bakery scaled without compromising quality

Operating from a central atelier, the bakery’s production runs 24/7, ensuring fresh products reach every store daily. The team works in well-coordinated shifts, upholding high-quality standards while scaling operations to meet increasing demand. With a diverse product range, including homemade chocolates, granola, melocakes, jams, and spreads, the bakery caters to customers throughout the day. They also collaborate with local suppliers to source fresh, regional ingredients, reinforcing their commitment to both quality and community support. 

Despite its success, rapid growth brought significant operational challenges that threatened efficiency and consistency. The bakery needed to refine its processes to maintain excellence while continuing to expand. 

Our solution

To tackle these operational inefficiencies, our senior operational excellence consultant designed a tailored three-step approach:

Structured Problem-Solving & Process Standardization:

• Introduced daily and weekly management meetings to proactively monitor and resolve operational challenges. 

• Implemented a structured reporting system to track recurring issues, shifting from reactive problem-solving to continuous improvement. 

• Developed a Lean Six Sigma framework to eliminate inefficiencies and reduce waste.
   

Data-Driven Optimization & Inventory Accuracy 

• Designed and integrated a custom Excel analytics tool, pulling ERP data to improve stock forecasting, procurement accuracy, and production scheduling. 

• Analyzed historical sales and production trends to optimize ingredient purchasing, reducing excess stock while ensuring key materials remained available. 

• Streamlined warehouse management processes, leading to improved inventory control and minimizing both stock shortages and surplus materials. 
   

Enhanced Labeling & Logistics Efficiency 

• Overhauled the labeling process by introducing better materials and optimizing barcode placement for faster, more accurate scanning. 

• Improved tracking and traceability of ingredients and finished products, ensuring seamless compliance with food industry regulations. 

• Implemented logistics process improvements, optimizing order fulfillment and delivery schedules across the company’s multiple locations. 

Results achieved

By embracing this structured approach to operational excellence, the bakery experienced measurable improvements: 

• Greater inventory accuracy, the improved ERP leads to more reliable procurement and production planning. 

• More proactive operations, reducing last-minute problem-solving and enabling smoother workflows. 

• Enhanced traceability and logistics, leading to faster and more accurate order fulfillment. 

• Higher workforce efficiency, as employees were empowered with structured processes and clearer problem-solving methodologies. 

• Stronger foundation for future growth, allowing the bakery to scale more effectively while maintaining operational excellence. 

The road ahead

By integrating structured processes and data-driven tools, this bakery has successfully transformed its operations, ensuring both efficiency and quality. Their commitment to tradition, combined with their innovative approach to branding, store experiences, and e-commerce, positions them as a leader in the Belgian baking industry. With streamlined workflows and improved decision-making capabilities, the company is now well-equipped to continue growing while maintaining the high standards that have made it a household name for generations.  

As the food industry evolves, businesses that prioritize operational excellence and embrace process improvements will secure a competitive edge. This bakery’s journey demonstrates how balancing tradition with smart innovation leads to sustainable success, ensuring that customers continue to enjoy premium, freshly baked products at the highest level of consistency and quality.