3rd Shift Bakery - Process Controller
hace 20 días
Manteno
Job Description JOB SUMMARY: As a Bakery Process Control Operator, you will play a critical role in ensuring that dough, crusts, and finished bakery products consistently meet food safety standards, customer specifications, and Urban Farmer’s net-content requirements. This position supports bakery production by performing on-line weight and quality inspections, verifying ingredients and formulas, monitoring equipment performance, and documenting all findings. You will work closely with Mixing, Sheeting/Press, Oven, and Packaging teams to ensure products meet all regulatory and quality expectations from raw ingredients through finished goods. Essential Duties and Responsibilities: Statistical Process Control (SPC) & Weight Monitoring • Develop, maintain, and update SPC weight sheets for dough balls, pressed crusts, baked crusts, and finished goods., • Conduct weight checks at required intervals (e.g., every 30 minutes or as outlined in SOP)., • Ensure weights fall within specified upper and lower control limits and take action when results fall outside those limits., • Trend data to identify recurring issues such as dough inconsistency, improper divider settings, or press variation., • Perform scale calibrations prior to shift start and throughout shift as required by SQF/QA guidelines., • Confirm proper functioning of dough height gauges, thermometers, moisture meters, timers, and metal detection verification tools., • Document calibration results and immediately report any equipment malfunction to Maintenance, QA, and Supervisors. Mixing • Verify ingredient lot codes match the formula and recipe sheet., • Confirm ingredient weights in batches fall within tolerances., • Check dough ball weights and ensure uniformity between stations., • Verify crust diameter, thickness, and shape meet spec., • Check for signs of sticking, tearing, or uneven pressing., • Document oven temperatures, bake time, and belt speed., • Inspect baked crust color, height, texture, moisture level, and bubble formation., • Confirm crusts reach required cooling temperature prior to packaging., • Ensure correct film, labels, and allergen identifiers are used., • Confirm net weights, label accuracy, and seal integrity on packaged items., • Check that all ingredients staged for the shift match the approved BOM (Bill of Materials)., • Ensure correct allergen controls are followed (e.g., gluten-free, dairy-free areas)., • Confirm proper FIFO rotation and documentation of lot codes., • Record all test data weights, temperatures, measurements, bake checks—into electronic tablets in real time., • Ensure accuracy, clarity, and completeness of digital entries for QA review., • Upload photos (if needed) of discrepancies, product defects, or out-of-spec observations., • Analyze trends in weights, dough performance, bake consistency, and finished goods quality., • Prepare shift reports summarizing:, • Out-of-spec weights, • Bake quality issues, • Ingredient discrepancies, • Equipment calibration issues, • Process deviations, • Immediately notify Production Supervisors and QA of any non-conforming product or potential food safety hazard., • Hold or stop production when necessary until corrective actions are completed., • Assist with rework decisions, hold tags, and product disposition documentation., • Follow all GMP rules, including handwashing, PPE, and allergen control procedures., • Adhere to SQF, HACCP, FDA, and bakery-specific food safety regulations., • Report any food safety, sanitation, or safety concerns immediately., • Participate in internal audits, mock recalls, and maintenance walk-throughs when requested., • Participate in root-cause analysis for quality or process deviations., • Perform additional tasks requested by Production, QA, or Management. QUALIFICATION REQUIREMENTS: • High School Diploma or equivalent is required., • Self-motivated with strong leadership skills and the ability to work independently with minimal supervision., • Proficient in using test equipment such as Quantum meters, Bostwick meters, weight scales, calipers, thermometers, rulers, and calculators., • Capable of performing basic math calculations with the aid of a calculator., • Excellent organizational skills with a demonstrated ability to analyze, interpret, and graph data on SPC documents., • Strong oral and written communication skills to ensure compliance with quality standards and effective issue resolution., • Basic computer skills, including proficiency in using tablets and familiarity with MS Word and Excel. Bilingual (English/Spanish) is a plus. PHYSICAL DEMANDS: • Ability to regularly lift and carry product samples weighing up to 20 lbs., • Capability to perform tasks in varying working conditions, including hot and cold environments., • Must wear assigned personal protective equipment (PPE) and adhere to sanitation procedures., • Ability to stand or walk for at least 8 hours to reach workstations. WORK ENVIRONMENT: This position works in a manufacturing environment with variable temperature and loud noises from machinery and equipment alarms. The incumbent will be exposed to loud noises and alarms from equipment and machinery 3rd