The Smucker’s company challenged Industrial Controls Automation to help it reduce the amount of bread used to make its Uncrustables brand of frozen peanut butter and jelly sandwiches. We took our usual comprehensive approach in reviewing the company’s entire production process. ICA designed and implemented a Cognex machine vision systems integration module to collect the data needed to evaluate how the product was made. The sophisticated Cognex remote equipment monitors and sensors measured dozens of qualitative and quantitative parameters at several positions along the production. The system compiled the data and reported it – along with images – through an FTP server. After weeks, we had collected enough data to make statistically relevant determinations on bread use. The company determined that it could maintain safety and product quality while saving up to $1 million per year by implementing changes to its upstream processes and bread loaf size to minimize waste.