Manufacturing turtles is a variable process, given the direct value-added materials: caramel, pecans, and chocolate. The turtle volume inconsistencies are apparent during the flow wrapping process because oversized turtles are rejected at a 3D Profile Station. The 3D Profile Station has subjective setpoints; therefore, operators may adjust the setpoints as they see fit. However, the operators should not significantly deviate from the centreline check sheet. The results yielded that operations are rejecting 100% oversized turtles and not attempting to package one over-sized turtle with two regular turtles. Thus, they are increasing waste; the recommendation includes relaxing the 3D Profile Station to admit slightly larger turtles assuming the likelihood that two regular turtles will fit within the same flow wrapper.
