Improved Applesauce Yields through

Design of Experiments (DOE)

Karl Hofman

Director – Rapid Continuous Improvement

Dr Pepper Snapple Group

3 Takeaways

2

Premium Tea

Gourmet CSDs

Juice & Juice DrinksFlavored CSDs

DPS is the Market Leader in many Categories

Mixers

3

Rapid Continuous Improvement (RCI)

A Culture Change Journey

4

We are creating a culture of breakthrough change by:

•Setting breakthrough goals (GOAL deployment)

•Measuring progress and addressing root cause (CAP)

•Developing Lean leaders (tracks)

5

5,300 participants -- 500 Kaizens – 100 locations

5

RCI Results

Balanced Approach to RCI:

• Safety – 37% reduction in recordables

• Quality – Consumer complaints down 25%

• Delivery – Fill Rate 99.9%

• Productivity – Reduced warehouse

footprint by 2.5MM ft2 (25%)

• Growth – +50 bps in WD SSMP share

Sustaining our World class status in Asset Utilization

58%

lower

than

peers

Improving Applesauce Yield

Using DOE and Minitab to Drive Improvement

Williamson, NY – Home of Motts’ Applesauce

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Multiserve Applesauce

(MSAS) Line

Singleserve Applesauce

(SSAS) Lines (3)Pouch Lines (2)

Applesauce Process Flow Overview

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KPIV's (X's) KPOV's (Y's)

Ratio Ratio of Bertocchi

Local Rate (throughput) / Chopped Fruit

Speed of Auger

Rotor Speed Bertocchi apple stream

Auger Speed Apple waste

Rotopulse Speed

Local Rate (throughput)

Speed

Screen Size Chopped Apples

Local Rate (throughput)

Apple Size

Speed Bertocchi/

Condition of Stator & Chopped Apples

Temperature

Local Rate (throughput) Heated Sauce

Temperature Heated Sauce

Local Rate (throughput)

Pressure

Cooked Sauce

Cook Time Cooked Sauce

Clearance of Screens Cooked Sauce

Clearance of Paddles

Position of Paddles

Screensize

Cooked Sauce

Waste

Applesauce Process Flow

Start

Apple Hoppers

Chopper

Bertocchi

End

PC Pump

Steam Pick 1

Steam Pick 2

Back Pressure Valve

Cook Tank

Finisher

Cooked Sauce heading to Pot

Finisher Waste Stream

Cooked Sauce to the Lines

DOE #1

DOE #2

Bertocchi Extractor – Description

The apple extraction processes for all applesauce lines in

Williamson incorporate the use of a specific brand of extractor

known as a Bertocchi extractor. Pictures of the Bertocchi used for

the MSAS line and SSAS lines are shown below with key

components identified:

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Bertocchi Unit

(opened with rotor and screen removed)

Bertocchi Rotor and

Screen

(removed and separated)

Rotor

Screen

Yield Loss/Waste Measurement

A manual yield loss measurement process was developed enabling

the team to directly measure the waste at each Bertocchi unit (MSAS

and SSAS):

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1. Bertocchi waste

chute modification

allows capture of

waste stream

2. Timed waste

collection

3. Weight

measured and

yield loss

calculated based

on output rate

Manual waste measurement process enables analysis of Bertocchi parameters to optimize

performance and reduce losses. Same method is applied to the finisher process.

Question? Is this an acceptable measurement system? Need to perform an MSA….

Yield Loss/Waste Measurement

• Initial Gage R&R study

conducted with 3 operators as

a nested study and using 15

second measurement intervals

Gage R&R Study - Nested ANOVA

Gage R&R (Nested) for Result

Source DF SS MS F P

Operator 2 7.7205 3.8602 0.34504 0.733

Batch (Operator) 3 33.5631 11.1877 5.28396 0.040

Repeatability 6 12.7038 2.1173

Total 11 53.9873

Gage R&R

%Contribution

Source VarComp (of VarComp)

Total Gage R&R 2.11729 31.83

Repeatability 2.11729 31.83

Reproducibility 0.00000 0.00

Part-To-Part 4.53520 68.17

Total Variation 6.65249 100.00

Study Var %Study Var

Source StdDev (SD) (6 × SD) (%SV)

Total Gage R&R 1.45509 8.7305 56.42

Repeatability 1.45509 8.7305 56.42

Reproducibility 0.00000 0.0000 0.00

Part-To-Part 2.12960 12.7776 82.57

Total Variation 2.57924 15.4755 100.00

Number of Distinct Categories = 2

Yield Loss/Waste Measurement

• Repeat Gage R&R study

conducted with 2 operators as

a nested study and using 30

second measurement intervalsGage R&R (Nested) for Results

Source DF SS MS F P

Operator 1 0.018 0.0176 0.000 0.987

Sample (Operator) 2 108.542 54.2709 111.455 0.000

Repeatability 12 5.843 0.4869

Total 15 114.403

Gage R&R

%Contribution

Source VarComp (of VarComp)

Total Gage R&R 0.4869 3.49

Repeatability 0.4869 3.49

Reproducibility 0.0000 0.00

Part-To-Part 13.4460 96.51

Total Variation 13.9329 100.00

Study Var %Study Var

Source StdDev (SD) (6 × SD) (%SV)

Total Gage R&R 0.69780 4.1868 18.69

Repeatability 0.69780 4.1868 18.69

Reproducibility 0.00000 0.0000 0.00

Part-To-Part 3.66688 22.0013 98.24

Total Variation 3.73268 22.3961 100.00

Number of Distinct Categories = 7

Bertocchi Extraction – Screen Life

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• Current practice for Bertocchi process is to replace mechanical

screen at 1 month (SSAS) and 2 month (MSAS) intervals.

• Comparison of older (end of life) screen and new (beginning of life)

screen showed significant waste differences (simple comparative

experiment on MSAS Bertocchi unit of old vs. new screen):

Screen life impacts yield

significantly. Comparison of old

vs. new screen on the MSAS

Bertocchi showed a ~60% improvement.

Old Screen MSAS

New Screen MSAS

0.020.010.00-0.01-0.02-0.03-0.04-0.05

MS

AS

Scre

en

Yield Loss (Normalized)

Boxplot of Yield Loss (Normalized) vs MSAS Screen

Old Screen MSAS

New Screen MSAS

0.0300.0250.0200.01 50.01 0

P-Value 0.678

P-Value 0.506

Multiple Comparisons

Levene’s Test

MS

AS

Scre

en

Test for Equal Variances: Yield Loss (Normalized) vs MSAS ScreenMultiple comparison intervals for the standard deviation, α = 0.05

If intervals do not overlap, the corresponding stdevs are significantly different.

Mood Median Test: Yield Loss (Normalized) versus MSAS Screen

Mood median test for Yield Loss (Normalized)

Chi-Square = 6.56 DF = 1 P = 0.010

Individual 95.0% CIs

MSAS Screen N≤ N> Median Q3-Q1 +---------+---------+---------+------

New Screen MSAS 5 0 -0.0293 0.0237 (---------*--------)

Old Screen MSAS 3 7 0.0051 0.0131 (-----*--)

+---------+---------+---------+------

-0.045 -0.030 -0.015 0.000

Overall median = 0.0000

* NOTE * Levels with < 6 observations have confidence < 95.0%

A 95.0% CI for median(New Screen MSAS) - median(Old Screen MSAS): (-0.0523,-0.0200)

Bertocchi Extraction – DOE #1

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• Evaluation of equipment components showed screen life impact on yield – what about

process set-up and operating conditions?

• DOE (Design of Experiments) allows us to evaluate multiple process inputs, determine

which inputs are critical and then reduce waste by optimizing those critical inputs in a

minimal number of experimental runs.

• We identified 4 key inputs to evaluate (Bertocchi feed rate, Rotor Speed, Infeed Auger

Speed and Rotopulse Speed). The optimal DOE design was determined to be a 4 factor, 1/2

fractional factorial design with 2 center points and 2 replicates for a total of 18 runs – See

Table Below:

This DOE was

performed in

March 2015 on the

MSAS Bertocchi

unit with a new

screen using the

manual method of

waste

measurement

Bertocchi Extraction – DOE #1

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DOE results showed that Rotor Speed was the main factor affecting waste with Bertocchi

Feed Rate having a minor impact on waste compared to Rotor Speed. All other factors

had insignificant impact on waste.• Rotor Speed (B) is the major

factor affecting waste

• Bertocchi feed rate (A) is a minor

factor affecting waste

• Other factors (C&D) and

interactions do not impact waste

• Increasing Rotor Speed

significantly reduces waste

• Decreasing Bertocchi Feed Rate

slightly reduces waste

Evaluating the DOE #1 Model for Bertocchi Yield

• Evaluation of power of the experiment and residuals

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The power of the experiment is 74% and

reasonable given the nature of our

product (it’s applesauce). The presence

of heteroscedasticity in the residuals

was identified but not concerning after

replicating optimal settings post DOE –

Bottom line was that the DOE yielded a

positive result that was demonstrated

and sustained in process post DOE.

Power and Sample Size

2-Level Factorial Design

α = 0.05 Assumed standard deviation = 0.34

Factors: 4 Base Design: 4, 8

Blocks: none

Including a term for center points in model.

Center Total

Points Effect Reps Runs Power

2 0.5 2 18 0.744813

Putting DOE #1 Results into Practice

• Prior to the DOE, Bertocchi extractor screens were replaced based on time and

multiple inputs on the Bertocchi extractor were adjusted to reduce losses with

unpredictable and inconsistent results.

• Post DOE, it was established that screen wear and rotor speed for the Bertocchi

extraction process were the only critical inputs affecting yield. Control charts were

established on the Bertocchi waste stream to monitor yield at a set frequency and

adjust rotor speed as needed to maintain process control until screen replacement

was necessary.

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An I-MR Chart is used to track

yield loss at the Bertocchi

extraction process based on

waste stream measurement. As

yield loss increases, the

Bertocchi rotor speed is

adjusted until reaching it’s

practical process limit then the

screen is changed. Note that as

the process has continued, the

UCL/LCL have tightened,

showing a very consistent

process yield.

DOE #2 – Chopping and Finishing Process

• The second DOE was conducted on the chopping/finishing stream that is

mixed with the Bertocchi stream to make our MSAS and SSAS products.

The key factors considered were Bertocchi ratio (ratio of Bertocchi stream

to chopped/finished stream) temperature (for chopped/finished stream)

and tank level (for cooking tank for chopped/finished stream).

• Based on the factors and perceived significant interactions, a 2 level 3

factor full factorial design was selected with 2 center points and 2

replicates for a total of 18 runs for DOE #2.

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This DOE was

performed in

July 2016 on

the MSAS line

using a new

screen for the

finisher

process

Run # StdOrder RunOrder CenterPt Blocks Ratio (Bertocchi) Cook Temp (Pick 1) Cook Tank Level

1 17 4 0 1 80 220 2

2 13 1 1 1 70 210 3

3 9 2 1 1 70 210 0

4 8 3 1 1 90 230 3

5 10 5 1 1 90 210 0

6 5 6 1 1 70 210 3

7 2 7 1 1 90 210 0

8 11 8 1 1 70 230 0

9 15 9 1 1 70 230 3

10 12 10 1 1 90 230 0

11 6 11 1 1 90 210 3

12 1 12 1 1 70 210 0

13 7 13 1 1 70 230 3

14 4 14 1 1 90 230 0

15 14 16 1 1 90 210 3

16 16 17 1 1 90 230 3

17 3 18 1 1 70 230 0

18 18 15 0 1 80 220 2

DOE #2 Results

• DOE #2 showed that the only significant factor affecting overall process yield was

the ratio of Bertocchi stream to chopped/finished stream. The higher the ratio, the

lower the yield losses.

• Evaluation of the model showed no issues with residuals and a power of 74% which

was acceptable (again, it’s applesauce)

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Power and Sample Size

2-Level Factorial Design

α = 0.05 Assumed standard deviation = 0.017

Factors: 3 Base Design: 3, 8

Blocks: none

Including a term for center points in model.

Center Total

Points Effect Reps Runs Power

2 0.025 2 18 0.744813

Next Steps

• Increase the Bertocchi to Chopped/Finished

Ratio to further optimize yield

•Shore up measurement system (perform further

MSA studies to identify where we can reduce

gage error)

• Implement similar process controls as

Bertocchi (I-MR charting/SPC) on yield losses at

finishing process step

•Analyze incoming apple crop to understand key

inputs and identify potential opportunities to

further improve yields

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3 Takeaways

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Questions?

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