The sample of a production line modification in a way that can improve productivity and at the same time improve the quality of the product.

1. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 1
Tortilla Line Improvement Project
H-E-B Snacks Factory
Roman Yakhin
UHV-Victoria
MGMT-6355-Operations Management Creating Competitive Advantage
Aug-03-2016
The Instructor: Dr. Jie Yang

2. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 2
Table of Contents:
1. Abstract-------------------------------------------------------------------------3
2. Background Information----------------------------------------------------4
3. Problem Description----------------------------------------------------------6
4. OM/Concepts Tools------------------------------------------------------------6
5. Application of OM/Concepts Tools ----------------------------------------7
6. Analysis of Expected Results ------------------------------------------------8
7. Appendix-Excel sigma calculations-----------------------------------------9
8. Reference-------------------------------------------------------------------------10

3. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 3
Abstract
The goal of this project is to improve operations of the Tortilla Lane at H-E-B’s snacks
factory in San Antonio, Texas. This project is based off my experience there as a quality
assurance technician. The project has multiple objectives:
1. Reduce the labor needed to operate the line
2. Maximize the output
3. Reduce the number of defects due to breakage
4. Reduce variations in the amount of salt coverage
The project addresses all of these issues by modifying the line in a way that can improve
productivity and at the same time improve the quality of the product.

4. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 4
Background Information
The Current Line set up
The current fryer setup enables the snack factory to make 2,400 pounds of tortilla chips
an hour, which is then seasoned via 2 of a possible 3 active tumblers.
The product travels upstairs to the Tumblers, which are large metal drums that spin at a
very fast rate while dispensing salt. The amount of salt applied at Tumbler #1 is different from
Tumbler #1
(1 operator)
Amount of salt =A
Packing Line #1
(1 operator)
Tumbler #2
(1 operator)
Amount of salt =B
Tumbler #3
DOWN
Fryer (1 operator)
Is set at 2/3 of its capacity
at 2400 LB/HR
Packing Line #3
DOWN
Packing Line #2
(1 operator)

5. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 5
the amount of salt applied at Tumbler #2. Tumbler #3 stays down and is used only as a backup.
The production team has tried, and failed to run all 3 Tumblers at the same time. The issue is
they could not synchronize the flow of the product with the speeds of all 3 tumblers in order to
apply salt correctly.
Tumbler:
After passing through the Tumblers the product goes downstairs to the packing lines. Two
packaging lines are used with 1 worker operating each of them.

6. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 6
Problem Description
The Tortilla line at H-E-B’s snacks factory produces product with 2 major defects. The
chips have a lot of breakage. A lot chips get broken while being spun inside the tumbler at high
speed. The chips have a lot of variation in the amount of salt they have. Some chips have too
much salt, and some have very little. This leads to dissatisfied customers and loss of the
company’s reputation. The fryer is not operating at its full capacity, because the salt distribution
is very difficult to control, at the current set up. An individual operator must be assigned to each
tumbler, because the speed of the tumbler must be constantly adjusted to the flow of the product
to achieve a steady salt coverage. The line needs five workers to be operational.
OM/Concepts Tools
I used a cost and effect method known as a fishbone or Ishikawa diagram to identify the
cause of the quality and productivity issues. They were as follows: Measurements - Titrator, lab
equipment used to measure salt content, Machine-Tumbler, Methods-Applying salt upstairs via
tumblers, Material-Salt, Mother Nature-Humidity, Man Power-Operators.
Machine
Tumbler
Methods
Applying salt upstairs
Materials
Salt
Man Power
Operators
Mother Nature
Humidity
Measurements
Titrator
Not consistent
Salt Distribution,
Broken Chips,
Low Output

7. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 7
I have also used Sigma calculation for salt distribution based on the present and proposed
production setup. I used Standard Deviation(Sigma) to numerically represent amount of
deviation.
Application of OM/Concepts Tools
I have eliminated Measurements, Materials, Mother Nature, and man Power as possible
causes of problems. I have identified 2 causes for the issue, the Method and the Machine. I have
calculated Sigma for the salt distribution before and after (Apendix).
The proposed solution is to replace the use of tumblers for salted chips with an integrated
salter system downstairs, right after they exit the fryer. Tumblers will still have to be used for
Nachos and Jalapeno chips, but they will not be used for regular salty chips.
Integrated salter system(currently only on the potato line)

8. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 8
The Proposed Line set up
Analysis of Expected Results
The Old System The New System Benefits & Explanation
Labor 5 workers 4 workers 1 worker is freed, because no
need to constantly monitor
tumblers.
The Output 2,400 LB/HR 3,600 LB/HR The fryer can be maxed out
because it will not have to be
in sync with tumblers rotation
anymore. The output will be
increase by 33.33%.
Breakage A lot of breakage Not too much
breakage
The amount of breakage will
be reduced, because the chips
will not have to be spun in
tumblers anymore.
The Variations in
Salt Distribution
(Estimates are in
Excel)
Each line produces
chips with deferent
salt amount.
All line produces
chips with the
same amount of
salt.
The variations will reduce
because chips on all 3 lines
will have the same amount of
salt.
Packing Line #1
(1 operator)
Fryer (1 operator)
Set to full capacity at
3,600 LB/HR
Packing Line #3
(1 operator)
Packing Line #2
(1 operator)
Integrated
Salter
System

9. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 9
Installing the integrated salter on the tortilla line will provide multiple process
improvement benefits.
Appendix-Excel sigma calculations

10. Tortilla Line Improvement Project at H-E-B’s Snacks Factory 10
References
 Tague, N. (2005). The Quality Toolbox, Second Edition, ASQ Quality Press, 2005, pages
247–249. Retrieved August 01, 2016, from http://asq.org/learn-about-quality/cause-
analysis-tools/overview/fishbone.html.
 Byrne, A., & Womack, J. P. (2013). The lean turnaround: How business leaders use lean
principles to create value and transform their company. New York: McGraw-Hill.
 Sanghera, P. (2009). 90 days to success as a project manager. Boston, MA: Course
Technology.
 Brussee, W. (2010). Six Sigma on a budget: Achieving more with less using the
principles of Six Sigma. New York: McGraw-Hill.
 Standard Deviation Formulas. Retrieved august 04,2016, from
https://www.mathsisfun.com/data/standard-deviation-formulas.html