(A double-check is performed by systematically weighing a bag on a scale to determine if the proper weight is being loaded by the weight-feeder. If there is significant deviation from 50 pounds, corrective adjustments are made to the weight-release mechanism.) 2. What procedures would you recommend to maintain proper quality control? Source: Professor Jerry Kinard, Western Carolina University, Reprinted with permission Frito-Lay's Quality Controlled Potato Chips Video Case assurance staff. They watch all aspects of quality, including training employees on the factory floor, monitoring automated processing equipment, and developing and updating statistical process control (SPC) charts. The upper and lower control lim- its for one checkpoint, salt content in Lay's chips, are 2.22% and 1.98%, respectively. To see exactly how these limits are created using SPC, watch the video that accompanies this case. Frito-Lay, the multi-billion-dollar snack food giant, produces bil- lions of pounds of product every year at its dozens of U.S. and Canadian plants. From the farming of potatoes in Florida, North Carolina, and Michigan-to factory and to retail stores, the ingredients and final product of Lay's chips, for example, are inspected at least 11 times in the field, before unloading at the plant, after washing and peeling, at the sizing station, at the fryer, after seasoning, when bagged (for weight), at carton filling in the warehouse, and as they are placed on the store shelf by Frito- Lay personnel. Similar inspections take place for its other famous products, including Cheetos, Fritos, Ruffles, and Tostitos. In addition to these employee inspections, the firm uses pro- prietary vision systems to look for defective potato chips. Chips are pulled off the high-speed line and checked twice if the vision system senses them to be too brown. The company follows the very strict Standards of the American Institute of Baking (AIB), standards that are much tougher than those of the U.S. Food and Drug Administration. Two unan- nounced AIB site visits per year keep Frito-Lay's plants on their toes. Scores, consistently in the excellent" range, are posted, and every employee knows exactly how the plant is doing. There are two key metrics in Frito-Lay's continuous improve- ment quality program: (1) total customer complaints (measured on a complaints per million bag basis) and (2) hourly or daily sta- tistical process control scores (for oil, moisture, seasoning, and salt content for chip thickness, for fryer temperature, and for weight). In the Florida plant, Angela McCormack, who holds engineering and MBA degrees, oversees a 15-member quality Discussion Questions 1. Angela is now going to evaluate a new salt process delivery sys- tem and wants to know if the upper and lower control limits at 3 standard deviations for the new system will meet the upper and lower control specifications noted earlier. The data (in percents) from the initial trial samples are: Sample 1: 1.98, 2.11, 2.15, 2.06 Sample 2: 1.99, 2.0, 2.08, 1.99 Sample 3: 2.20, 2.10.2.20, 2.05 Sample 4:2.18, 2.01, 2.23. 1.98 Sample 5: 2.01,2.08, 2.14.2.16 Provide the report to Angela 2. What are the advantages and disadvantages of Frito-Lay driv- ers stocking their customers' shelves? 3. Why is quality a critical function at Frito-Lay? *You may wish to view the video that accompanies this case before answering these questions