Hirzel Canning ProjectHirzel Canning ProjectTeam 2Team 2

Phase II Final PortfolioPhase II Final Portfolio

Industrial Technologist’s Toolkit for Technical Management CD:Industrial Technologist’s Toolkit for Technical Management CD:Quality Analysis Data ToolsQuality Analysis Data Tools

QS 326 Spring 2004QS 326 Spring 2004

Team 2Team 2

Eric FritzEric FritzJim GallagherJim GallagherMarc RairdenMarc Rairden

Robert RitzmanRobert RitzmanMarc ThomasMarc ThomasTeri Jo WiseTeri Jo Wise

Bowling Green State UniversityBowling Green State University

Introduction/DescriptionIntroduction/Description At the start of the Spring 2004 semester, a project was At the start of the Spring 2004 semester, a project was

launched between the BGSU College of Technology, launched between the BGSU College of Technology, School of Family and Consumer Sciences, and the School of Family and Consumer Sciences, and the Hirzel Canning Company.Hirzel Canning Company.

The project scope is to develop a working Quality The project scope is to develop a working Quality Management System model for the small to mid-sized Management System model for the small to mid-sized food manufacturing industry. This system is abbreviated food manufacturing industry. This system is abbreviated FQSSMS (Food Quality, Safety, and Security FQSSMS (Food Quality, Safety, and Security Management System).Management System).

This presentation summarizes the work of the This presentation summarizes the work of the undergraduate QS 326 Team 2 students during the undergraduate QS 326 Team 2 students during the semester. It includes course work, project work, and the semester. It includes course work, project work, and the progression of the team from inception through the end progression of the team from inception through the end of the semester.of the semester.

Hirzel BackgroundHirzel BackgroundHirzel was founded in 1923. One of their first products was

sauerkraut, that was sold in wooden kegs and barrels. The company grew steadily and is now operated by the third and fourth generations of the family. Currently, Hirzel has 3 processing plants, with greenhouse and farming operations that produce the raw product. As many as 30 independent growers supply tomatoes. Hirzel also has over 100 items that are available in both retail and foodservice sizes, packed in cans, glass, and flexible packaging. They also have a storage facility for tomato product (diced, crushed, puree) that is unique to the organization. Their “house brands” are Dei Fratelli tomato products, and Silver Fleece and Star Cross sauerkraut. The company produces multiple products for various entities, labeling the product with the different brand’s labels. Tomatoes are the foundation product/ingredient, and their ‘busy season’ is the growing and harvest period of approximately May through early October.

The TomatoesThe Tomatoes The very best quality tomatoes are used in The very best quality tomatoes are used in

the canned whole tomato product.the canned whole tomato product. Canned whole tomatoes are produced Canned whole tomatoes are produced

with the quickest ‘received to finished with the quickest ‘received to finished product’ time. They are the only product product’ time. They are the only product that is cooked/sterilized in the can, after that is cooked/sterilized in the can, after sealing.sealing.

The tomato processes are governed under The tomato processes are governed under ‘high acid’ food production regulations, for ‘high acid’ food production regulations, for products with a pH level of 4.8 or less.products with a pH level of 4.8 or less.

The Tomatoes (continued)The Tomatoes (continued)

‘‘High Acid’ processes are far less High Acid’ processes are far less regulated than other food production regulated than other food production processes, due to the fact that low pH is processes, due to the fact that low pH is an environment in which food bacteria an environment in which food bacteria such as boccilism can not exist.such as boccilism can not exist.

The secondary processes (other than The secondary processes (other than canned whole tomatoes) are sterilized by canned whole tomatoes) are sterilized by aseptic method. This is a heating, holding, aseptic method. This is a heating, holding, and cooling process prior to sealing.and cooling process prior to sealing.

The Tomatoes (continued)The Tomatoes (continued)

The heated product sterilizes the container The heated product sterilizes the container and lid in an aseptic process.and lid in an aseptic process.

The following slides exhibit the physical The following slides exhibit the physical attributes of incoming tomatoes, how they attributes of incoming tomatoes, how they are graded, and an example aseptic are graded, and an example aseptic process flow chart of diced tomato process flow chart of diced tomato product. Unacceptable tomatoes are product. Unacceptable tomatoes are referred to as “culls”, and rejected.referred to as “culls”, and rejected.

#1#1#2#2#3#3CullsCullsCullsCullsCullsCulls

Culls Culls Culls #3 #2 #1

Phase I PortfolioPhase I Portfolio

Industrial Technologist’s Toolkit:Industrial Technologist’s Toolkit:

Tool #15Tool #15 “ “Statistical Foundations for Data-Based Improvement, Lean,Statistical Foundations for Data-Based Improvement, Lean,

Six Sigma Solutions”Six Sigma Solutions”

Tool #16Tool #16 “ “Attribute Data, The Obvious Starting Point for Lean,Attribute Data, The Obvious Starting Point for Lean,

Six Sigma, Service”Six Sigma, Service” Tool #17Tool #17

““Variable Data, Comparisons to Attribute ChartingVariable Data, Comparisons to Attribute Charting for Six Sigma, Lean Service”for Six Sigma, Lean Service”

Phase II PortfolioPhase II Portfolio

Industrial Technologist’s Toolkit:Industrial Technologist’s Toolkit: Tool #18Tool #18

“ “Basic Measurement, Geometric Relationships, Broader Data-based Basic Measurement, Geometric Relationships, Broader Data-based Issues”Issues”

Tool #19Tool #19

““Gauge Repeatability and Reproducibility (R&R): Inspection and Gauge Repeatability and Reproducibility (R&R): Inspection and Measurement as Critical Services for Lean”Measurement as Critical Services for Lean”

Tool #20Tool #20

““Capability, Charts, and Quality Characteristics Analysis: Capability, Charts, and Quality Characteristics Analysis: Transforming Six Sigma and Lean”Transforming Six Sigma and Lean”

Team 2 Sub-GroupsTeam 2 Sub-Groups Bulk ingredients:Bulk ingredients: Jim and Marc R Jim and Marc R

(Tomatoes, peppers, cabbage)(Tomatoes, peppers, cabbage)

Other ingredients:Other ingredients: Eric and Marc T Eric and Marc T(corn syrup, vinegar, spices, etc.)(corn syrup, vinegar, spices, etc.)

Traceability:Traceability: Teri and Robert Teri and Robert

( Accountability in the processing ( Accountability in the processing flow, flow, all incoming ingredients)all incoming ingredients)

Bulk IngredientsBulk Ingredients

Tomatoes, cabbage, peppersTomatoes, cabbage, peppers Incoming ingredients from Hirzel’s contract Incoming ingredients from Hirzel’s contract

farmers. For tomatoes, more than 6% farmers. For tomatoes, more than 6% culls is cause to reject an entire load.culls is cause to reject an entire load.

During prime season, top grade tomatoes During prime season, top grade tomatoes go from truck to can in approximately 10 go from truck to can in approximately 10 minutes, with the rest designated for other minutes, with the rest designated for other base products to be canned or stored.base products to be canned or stored.

Other IngredientsOther Ingredients

Vinegar, corn syrup, spices, etc.Vinegar, corn syrup, spices, etc. These other ingredients are utilized in the These other ingredients are utilized in the

various food product processes.various food product processes. The integrity and quality of these The integrity and quality of these

ingredients is ensured by certificates of ingredients is ensured by certificates of authenticity (COA’s).authenticity (COA’s).

Recipe software gives quantities needed, Recipe software gives quantities needed, and availability within plant.and availability within plant.

Traceability FindingsTraceability Findings There is not enough trash received with the bulk There is not enough trash received with the bulk

tomatoes to start a recycling program.tomatoes to start a recycling program. The county Auditor annually calibrates the scales.The county Auditor annually calibrates the scales. Annual training is provided for graders, but not much Annual training is provided for graders, but not much

turnover from year to year.turnover from year to year. Graded tomato information goes back to the farmers file Graded tomato information goes back to the farmers file

to ensure quality goods from each.to ensure quality goods from each. Special tamper-evident seals which break off if the trailer Special tamper-evident seals which break off if the trailer

door is opened are used for each box van load leaving door is opened are used for each box van load leaving the plant.the plant.

These seals are placed by the employee responsible for These seals are placed by the employee responsible for loading the truck.loading the truck.

The seal number is indicated on the paperwork and are The seal number is indicated on the paperwork and are documented on incoming inspection sheets as well.documented on incoming inspection sheets as well.

Traceability cont.Traceability cont.

An area for improvement would be as An area for improvement would be as follows:follows: Bulk wash outs: The trucking company only Bulk wash outs: The trucking company only

keeps records and is responsible for ensuring keeps records and is responsible for ensuring a food grade wash out.a food grade wash out.

The delivering truck furnishes the hoses and The delivering truck furnishes the hoses and stainless steel pump for unloading. Hirzel stainless steel pump for unloading. Hirzel Canning was not sure if the hoses were Canning was not sure if the hoses were included in the certification of food grade included in the certification of food grade wash.wash.

DescriptionDescription

A compilation of Team 2’s “best work” A compilation of Team 2’s “best work” from the course work Data Tool units. The from the course work Data Tool units. The emphasis is on defining Team emphasis is on defining Team structure/roles, what we have learned, structure/roles, what we have learned, how we have progressed, background on how we have progressed, background on the Hirzel project, and concluding whether the Hirzel project, and concluding whether we have met the objectives for the second we have met the objectives for the second half of the course.half of the course.

Relating Courseware to HirzelRelating Courseware to Hirzel

Go to the Hirzel Canning Company and obtain Go to the Hirzel Canning Company and obtain data/information.data/information.

Talk with the Managers of Hirzel to gather Talk with the Managers of Hirzel to gather perspective of operation, compile questions perspective of operation, compile questions applicable to tools and project.applicable to tools and project.

Talk to the workers with the ongoing problem to Talk to the workers with the ongoing problem to see there opinion. Observe process in see there opinion. Observe process in operation.operation.

Derive solutions, improvements from data.Derive solutions, improvements from data.

Toolkit Evaluation ProcessToolkit Evaluation Process

- Read the courseware information in the Read the courseware information in the Toolkits Toolkits

- Go over the Toolkit presentation and fill in Go over the Toolkit presentation and fill in the necessary information for the Toolthe necessary information for the Tool

- Add data/information from HirzelAdd data/information from Hirzel

- Go back, after more information is Go back, after more information is obtained, and update the portfolioobtained, and update the portfolio

Toolkit 15 HighlightsToolkit 15 Highlights

ISO 9000 & TS 16949 2002 basis for ISO 9000 & TS 16949 2002 basis for quality systemsquality systems

Sampling, gathering accurate data, Sampling, gathering accurate data, Attribute charting, & checklist systemsAttribute charting, & checklist systems

SPC,X-bar and R, Variable chartingSPC,X-bar and R, Variable charting Six Sigma, solving problems, reducing Six Sigma, solving problems, reducing

variation, and making improvements.variation, and making improvements.

Tool 16 HighlightsTool 16 Highlights

Statistical principals in qualityStatistical principals in quality Normal curve, variation, and std. dev.Normal curve, variation, and std. dev. Attribute dataAttribute data P chart stepsP chart steps Quality characteristics, accurate data and Quality characteristics, accurate data and

variable chartingvariable charting Team based problem solvingTeam based problem solving

Tool 17 HighlightsTool 17 Highlights

Sampling and Characteristics Sampling and Characteristics Attribute data reviewedAttribute data reviewed Constructing X bar and R chartsConstructing X bar and R charts Short or mini runs, pre-control and Short or mini runs, pre-control and

trendingtrending Attribute versus variable systemsAttribute versus variable systems Six sigma and lean assessedSix sigma and lean assessed

Tool 18 HighlightsTool 18 Highlights

Foundational metrology and measurement Foundational metrology and measurement issuesissues

Inspection system services in qualityInspection system services in quality Historical background on metrologyHistorical background on metrology Basic principles and devices for Basic principles and devices for

measurement and data collectionmeasurement and data collection GD&TGD&T Surface qualitySurface quality

Tool 19 HighlightsTool 19 Highlights

Gauges and instruments, lean, six sigma Gauges and instruments, lean, six sigma opportunitiesopportunities

Sampling issuesSampling issues Evaluating gauges, measurement errorEvaluating gauges, measurement error Traditional versus new approachesTraditional versus new approaches Evaluation of quality characteristicsEvaluation of quality characteristics Data and documentation for lean, six Data and documentation for lean, six

sigma, kaizensigma, kaizen

Tool 20 HighlightsTool 20 Highlights

Framework for capabilityFramework for capability Cp and Cpk definitionsCp and Cpk definitions 1.33 objectives1.33 objectives Out of control conditionsOut of control conditions Systematic use of data and charts: Systematic use of data and charts:

revisiting basic Six Sigmarevisiting basic Six Sigma Quality characteristics: Lean QualityQuality characteristics: Lean Quality

The EndThe End