Hirzel Canning Project

1. Hirzel Canning Project Team 2 Phase II Final Portfolio Industrial Technologist’s Toolkit for Technical Management CD: Quality Analysis Data Tools QS 326 Spring 2004

2. Team 2 Eric Fritz Jim Gallagher Marc Rairden Robert Ritzman Marc Thomas Teri Jo Wise Bowling Green State University

3. Introduction/Description • At the start of the Spring 2004 semester, a project was launched between the BGSU College of Technology, School of Family and Consumer Sciences, and the Hirzel Canning Company. • The project scope is to develop a working Quality Management System model for the small to mid-sized food manufacturing industry. This system is abbreviated FQSSMS (Food Quality, Safety, and Security Management System). • This presentation summarizes the work of the undergraduate QS 326 Team 2 students during the semester. It includes course work, project work, and the progression of the team from inception through the end of the semester.

4. Hirzel Background Hirzel 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.

5. The Tomatoes • The very best quality tomatoes are used in the canned whole tomato product. • Canned whole tomatoes are produced with the quickest ‘received to finished product’ time. They are the only product that is cooked/sterilized in the can, after sealing. • The tomato processes are governed under ‘high acid’ food production regulations, for products with a pH level of 4.8 or less.

6. The Tomatoes (continued) • ‘High Acid’ processes are far less regulated than other food production processes, due to the fact that low pH is an environment in which food bacteria such as boccilism can not exist. • The secondary processes (other than canned whole tomatoes) are sterilized by aseptic method. This is a heating, holding, and cooling process prior to sealing.

7. The Tomatoes (continued) • The heated product sterilizes the container and lid in an aseptic process. • The following slides exhibit the physical attributes of incoming tomatoes, how they are graded, and an example aseptic process flow chart of diced tomato product. Unacceptable tomatoes are referred to as “culls”, and rejected.

8. Culls Culls Culls #3 #2 #1 Culls Culls Culls #3 #2 #1

10. Industrial Technologist’s Toolkit: Tool #15 “Statistical Foundations for Data-Based Improvement, Lean, Six Sigma Solutions” Tool #16 “Attribute Data, The Obvious Starting Point for Lean, Six Sigma, Service” Tool #17 “Variable Data, Comparisons to Attribute Charting for Six Sigma, Lean Service” Phase I Portfolio

11. Phase II Portfolio Industrial Technologist’s Toolkit: • Tool #18 “Basic Measurement, Geometric Relationships, Broader Data-based Issues” • Tool #19 “Gauge Repeatability and Reproducibility (R&R): Inspection and Measurement as Critical Services for Lean” • Tool #20 “Capability, Charts, and Quality Characteristics Analysis: Transforming Six Sigma and Lean”

12. Team 2 Sub-Groups • Bulk ingredients: Jim and Marc R (Tomatoes, peppers, cabbage) • Other ingredients: Eric and Marc T (corn syrup, vinegar, spices, etc.) • Traceability: Teri and Robert ( Accountability in the processing flow, all incoming ingredients)

13. Bulk Ingredients • Tomatoes, cabbage, peppers • Incoming ingredients from Hirzel’s contract farmers. For tomatoes, more than 6% culls is cause to reject an entire load. • During prime season, top grade tomatoes go from truck to can in approximately 10 minutes, with the rest designated for other base products to be canned or stored.

14. Other Ingredients • Vinegar, corn syrup, spices, etc. • These other ingredients are utilized in the various food product processes. • The integrity and quality of these ingredients is ensured by certificates of authenticity (COA’s). • Recipe software gives quantities needed, and availability within plant.

15. Traceability Findings • There is not enough trash received with the bulk tomatoes to start a recycling program. • The county Auditor annually calibrates the scales. • Annual training is provided for graders, but not much turnover from year to year. • Graded tomato information goes back to the farmers file to ensure quality goods from each. • Special tamper-evident seals which break off if the trailer door is opened are used for each box van load leaving the plant. • These seals are placed by the employee responsible for loading the truck. • The seal number is indicated on the paperwork and are documented on incoming inspection sheets as well.

16. Traceability cont. • An area for improvement would be as follows: • Bulk wash outs: The trucking company only keeps records and is responsible for ensuring a food grade wash out. • The delivering truck furnishes the hoses and stainless steel pump for unloading. Hirzel Canning was not sure if the hoses were included in the certification of food grade wash.

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

18. Go to the Hirzel Canning Company and obtain data/information. Talk with the Managers of Hirzel to gather perspective of operation, compile questions applicable to tools and project. Talk to the workers with the ongoing problem to see there opinion. Observe process in operation. Derive solutions, improvements from data. Relating Courseware to Hirzel

19. Read the courseware information in the Toolkits Go over the Toolkit presentation and fill in the necessary information for the Tool Add data/information from Hirzel Go back, after more information is obtained, and update the portfolio Toolkit Evaluation Process

20. Toolkit 15 Highlights • ISO 9000 & TS 16949 2002 basis for quality systems • Sampling, gathering accurate data, Attribute charting, & checklist systems • SPC,X-bar and R, Variable charting • Six Sigma, solving problems, reducing variation, and making improvements.

21. Tool 16 Highlights • Statistical principals in quality • Normal curve, variation, and std. dev. • Attribute data • P chart steps • Quality characteristics, accurate data and variable charting • Team based problem solving

22. Tool 17 Highlights • Sampling and Characteristics • Attribute data reviewed • Constructing X bar and R charts • Short or mini runs, pre-control and trending • Attribute versus variable systems • Six sigma and lean assessed

23. Tool 18 Highlights • Foundational metrology and measurement issues • Inspection system services in quality • Historical background on metrology • Basic principles and devices for measurement and data collection • GD&T • Surface quality

24. Tool 19 Highlights • Gauges and instruments, lean, six sigma opportunities • Sampling issues • Evaluating gauges, measurement error • Traditional versus new approaches • Evaluation of quality characteristics • Data and documentation for lean, six sigma, kaizen

25. Tool 20 Highlights • Framework for capability • Cp and Cpk definitions • 1.33 objectives • Out of control conditions • Systematic use of data and charts: revisiting basic Six Sigma • Quality characteristics: Lean Quality

26. The End