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.
Alpha line is capable of producing Original, Bite, and Mini turtles. The management team began negotiating a new supply chain contract for pecans, it became apparent the current pecan size was too cumbersome for effective Bite production. The Research and Development Senior Manager suggested utilizing smaller pecans that would encourage turtle size consistency and decrease waste. However, many team members discarded the suggestions assuming the turtle volume [mm³] would decrease and the inconsistency is inherent.