It seems rather curious that Hostess Brands CEO Gregory Rayburn would have so much time to talk to the business press over the last week or so as his company was racing toward liquidation, but he did and the message was consistent. The unwillingness of the baker's union to take some 30% in compensation reductions was the cause of the demise of the Twinkie.
Don't get me wrong, unions in general and the bakers at Twinkie in particular are a useless relic of the past. Paying people $48,000 a year, along with a solid health plan and retirement benefits takes a lot of productivity to justify and unions are productivity killers. Regardless, the union didn't kill Hostess. That much is clear from a basic look at their business.
They are a private company so their financials aren't out there in the open, but looking over the numbers from the last few years when they were publicly traded, as well as the figures from their bankruptcy filings, the cost structure look something like this:
Now 15% for factory labor is on the high side for any product, especially bakery products, but when better than half the cost of a Twinkie has nothing to do with the value of a Twinkie it is pretty plain that Hostess' inability to make a profit has everything to do with management - or, more appropriately, mismanagement. It was something of an understatement when Food Industry expert David Pauker said, Hostess' brand name and recipes will "most likely will be purchased by a competitor that will bolt the additional sales to a more efficient delivery system." My guess is that pretty well describes just about everyone in their industry. Throw in the costs and profits of the grocery and convenience stores and, at best, 25 cents out of every dollar spent on Twinkies actually went into making the Twinkie - the rest went for something else.
Even the value adding chunk of the Hostess cost structure is overblown. Unprocessed sugar goes for about 19 cents a pound on the global market these days, but thanks to sugar tariffs that have been on the books since the Depression US companies pay nearly double that. At 19 grams of sugar per Twinkie X a half a billion Twinkies a year, Twinkie eaters have been paying better than $4 million a year just to prop up US sugar growers ... add in the sugar it takes to make Ho Ho's, Ding Dongs, snack cakes and the rest of the Hostess line-up and you are talking real money.
The liquidation of Hostess was written in the stars long before last week. Gergory Rayburn does thai sort of thing for a living. You can read some of his career highlights here, but the one thing glaringly missing from his resume is actually running anything profitably. He is a 'restructuring expert', which basically means he doesn't worry about running the business - just getting whatever he can out of it for the stockholders, regardless of where that leaves employees, customers, suppliers and much of anyone else connected with the business.
The details of the script for Hostess end were left up to him, but ending it was decided upon when he was brought in eight months ago. What we saw last week was little more than a clumsily executed stage play to blame the unions for a decade of mismanagement.
Everyone is predicting that Twinkies will live on, provided by someone else. I hope so. With such powerful forces aligned against me in my campaign to defend the American tradition of obesity I need all the Hostess products I can get, but Twinkies will only survive in the hands of someone who can make them with a much better value proposition. And make no mistake, like so many other 'brands' Hostess died of a pathetic value adding ratio, and that is 100% on the management of the company.
Original: http://www.idatix.com/manufacturing-leadership/the-anatomy-of-a-twinkie/