MEMO

TO: ANGELA MCCORMARK

FROM: BACH HOANG

SUBJECT: EVALUATE THE STATISTICAL PROCESS CONTROL IN FRITO-

LAY CASE

DATE: NOVEMBER 6TH, 2022

I am writing this memo to give a solid analysis of the statistical process control for the
salt content in our products. My analysis will compare our current upper control limits
(UCL) and lower control limits (LCL) with the new set of UCL and LCL to evaluate if the
new measurement can fulfill the current control requirements.

*The current limits: *The statistic provided are:

- UCL = 2.2 - Standard deviation: s = .07

- LCL = 1.98. - Each sample: n = 4

The outcomes of the methods are presented below, based on the size of the samples (n
= 4). To determine the values of UCL and LCL for the X-bar Chart and R- Chart, we
utilized the following formulas:

*X-bar Chart
*Notes:
UCL = x̿ + R̅*A2 x̿ is average of x̅
x̅ is average of observations in a sample
LCL = x̿ - R̅*A2
R̅ = average range of sample
*R-Chart A2 = 3 sigma constant for sample size of 4 = 0.729
UCL = D4*R̅
D3 = 3 sigma constant for sample size of 4 = 0
 LCL = D3 * R̅

A summary of value can be placed in the table below:

  x1 x2 x3 x4 ̅X R

Sample 1 1.98 2.11 2.15 2.06 2.08 0.17

Sample 2 1.99 2.00 2.08 1.99 2.02 0.09

Sample 3 2.20 2.10 2.20 2.05 2.14 0.15

Sample 4 2.18 2.01 2.23 1.98 2.10 0.25

Sample 5 2.01 2.08 2.14 2.16 2.10 0.15

Current Set Limits

X-bar-bar 2.09
UCL LCL
R-bar 0.16
2.22 1.98
Mean factor, A2 0.729

New Process Limits Upper range, D4 2.282

UCL LCL
Lower range, D3 0

2.203098 1.96690

  X-bar R UCLx LCLx UCLR LCLR

Sample 1 2.08 0.17 2.203098 1.966902 0.369684 0
Sample 2 2.02 0.09 2.203098 1.966902 0.369684 0
Sample 3 2.14 0.15 2.203098 1.966902 0.369684 0

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 Sample 4 2.10 0.25 2.203098 1.966902 0.369684 0
Sample 5 2.10 0.15 2.203098 1.966902 0.369684 0

X-bar
2.25
2.20 2.203098
2.15 2.10
2.10 2.09
2.05
2.00
1.95 1.966902
1.90
1.85
1.80
1 2 3 4 5

X-bar UCLx LCLx X-bar-bar

Range
0.40
0.369684
0.35
0.30
0.25
0.20 0.16
0.15 0.15
0.10
0.05
0.00 0
1 2 3 4 5

R UCLR LCLR R-bar

1. The improvement in variability Frito-Lay made by implementing SPC.

- The new system will use a better-quality management system, and the control
system will be improved. As a results, the new UCL and LCL values for the X-bar
map are lower than the previous ones.

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 - Furthermore, the whole range has dropped by 0.04; the UCL has declined by
0.02 (2.22 - 2.20), and the CLC has decreased by 0.02 (1.98 - 1.96), indicating a
significant increase.

2. The steps Karen Engels and Barbara Boudreau go through as part of a testing cycle.

- Step 1. Every 15 minutes Karen Engels collects three finished potato bags for salt
analysis.
- Step 2. The purpose of the salt analysis is to make sure that salt content must be
balanced. It has to be significant enough to achieve the desired flavor and to
satisfy consumer health concerns.
- Step 3. Each bag of chips is ground-up, weighted, dissolved in distilled water, and
filtered into a beaker to check the salt content.
- Step 4. Then the electronic salt analyzer will give the exact percentage of salt. 
- Step 5. Karen repeats that process with the other two bags.
- Step 6. Barbara Boudreau then collects the information for further analysis
- Step 7. Barbara averages the salt content of the three batches and comes up with
the sample mean. She plots the mean on this control chart, a special kind of graph
that lets her know when the salting process is out of control.

Best regards,
Bach