Jim Caples has worked in baking for 36 years, but his start in the industry was actually by chance. Driving by United States Bakery, (DBA) Franz Bakery in Seattle one day during high school, Caples decided to stop in and see if they were looking for help.
“I wasn’t actively searching for a career at the time, but something about the atmosphere of the bakery caught my attention,” he said. “They were hiring, so I took the opportunity, and from there, I fell in love with the craft. I began learning the basics and soon realized how much I enjoyed the science and precision involved in baking. That chance encounter turned into a career, and I’ve been passionate about baking ever since.”
Caples began in Franz’s sanitation department, which he said gave him a strong foundation in maintaining cleanliness and understanding the behind-the-scenes of an operation. From there, Caples worked his way up the ranks at the bakery, from the wrapping and shipping departments to eventual production roles including production manager, plant manager and, ultimately, operations manager.
“Each role allowed me to develop a deeper understanding of the entire bakery process, from production to logistics, and gave me valuable leadership experience,” he said. “This progression has not only helped me refine my skills but has also given me a deep appreciation for every aspect of bakery operations from the ground up.”
Today, Caples oversees two Franz bakeries producing more than 3 million lbs of dough each week. He said managing such a large-scale operation is both challenging and rewarding.
“I really enjoy the fast pace of the bakeries, as it keeps me engaged and constantly looking for ways to improve efficiency and quality,” he said. “The dynamic environment challenges me every day, which is something I thrive on.”
He added that mentoring the next generation of leadership at the bakery has been one of the most rewarding aspects of the role.
“I take great pride in helping them develop the skills and confidence they need to succeed, ensuring we have strong leadership at all levels,” he said.
Here, Caples shares the importance of quality assurance and how to ensure a strong quality assurance program.
How would you define quality assurance (QA) for a baking operation?
Quality assurance in our baking operation is all about implementing thorough processes and procedures to ensure that every product we make meets the highest standards of quality. This involves careful attention to detail at every stage, from ingredients to monitoring production processes and conducting regular checks throughout the baking cycle. We have set protocols in place for consistency, from temperature controls and mixing times to packaging. It’s crucial to maintain these standards not only to meet customer expectations but also to ensure food safety and optimize efficiency. By continuously reviewing and refining our quality assurance practices, we can consistently deliver top-quality products.
Why is QA increasingly important for bakers today?
Quality assurance is increasingly important today because customers are more discerning than ever. They not only want a high-quality product, but they also expect it at an affordable price. In such a competitive market, ensuring that our products meet both quality standards and cost efficiency is crucial. By maintaining rigorous quality assurance processes, we can consistently deliver products that meet customer expectations while also keeping production costs under control. This balance between quality and affordability is key to building trust with our customers and staying competitive in the industry.
What are the hallmarks of a strong QA program?
The hallmarks of a strong QA program are maintaining consistent processes and procedures day in and day out. It’s not just about having standards in place but ensuring those standards are followed at every step of the production process, every day. This consistency is key to ensuring that the quality of our products remains high, regardless of the volume or scale. Regular training, routine inspections and clear documentation help keep everyone on the same page so we can reliably deliver products that meet our quality standards.
What are some common QA errors you see bakers make? How can they be avoided?
Typically, when we encounter a quality issue it often traces back to a breakdown in our processes. This can happen due to a variety of reasons, such as employee error or a mechanical breakdown that causes a deviation from processing standards. It’s important for the team to ask the right questions — why, what, when — until we pinpoint exactly where the breakdown occurred. Identifying the root cause of these issues is crucial to resolving them and preventing future occurrences. By continuously analyzing and refining our processes, we ensure that we can quickly address any breakdowns and maintain the quality our customers expect.
How can bakers effectively respond when QA issues arise?
Bakers can effectively respond to QA issues by focusing on identifying the root cause of the problem. Once the root cause is identified, we can examine the process to see where it went off track. Whether it’s an issue with equipment, procedures or human error, understanding where the breakdown happened allows us to make the necessary adjustments. Encouraging this type of problem-solving mindset within the team not only helps resolve immediate issues but also strengthens the overall process, reducing the chance of future problems.
What is the value of training in ensuring QA/food safety?
The importance of training in QA and food safety cannot be overstated. Training provides the knowledge and skills necessary to ensure that everyone understands the standards and procedures that uphold product quality and safety. Beyond that, training empowers and engages employees by giving them the confidence to follow protocols accurately and make informed decisions. When employees are well-trained, they are more likely to take ownership of their roles, catch potential issues before they become problems and feel invested in the overall success of the operation. This engagement leads to a stronger team, better adherence to standards and, ultimately, a higher-quality product.
What can bakers do today to improve their QA?
To improve a QA program, it’s essential to prioritize continuous training and learning. As the industry evolves, so do regulations, and staying ahead of these changes is crucial for maintaining the high standards our customers expect. Future regulations may impact everything from ingredient sourcing to production processes, and if we aren’t proactive in staying informed, we risk falling behind. By continuously educating our teams and keeping them up to speed on what’s coming, we can ensure that we have the time and flexibility to adapt. This approach helps us maintain consistency in the products we deliver while meeting new regulatory requirements and keeping customer satisfaction at the forefront.
