The Transformation Process for Lays

Manufacturing
Lays Potato Chips Salted
Journey of Potato to a crunchy Salted Potato Chips

Quality of Quality of
Inputs Outputs
Monitored Monitored

Random Disturbances

Transformation
Process

Feedback Mechanism

INPUTS

 Ingredients OUTPUTS
 Plant and Machinery
 Premium Quality Potato
 Workers
Chips
 Electricity
 Packed Potato Chips
 Administrative Staff
 Fresh Tasty snacks for
 Packaging Material and
customers
Packaging Machinery
 Product ready for Revenue
 Managers and production
generation
Team
 Customer Satisfaction
 Office Infrastructure
 Quick light Snack
 Capital
 Product Lay’s Classic Salted
 Water
 Industrial Fryer
 Gas Supply
 Monitoring Equipment and
instruments
A transformation Process is defined as a process which converts the various inputs into
desired outputs of product and services. Here we are briefly describing the transformation
process of Frito lays which comes under food products Industry. We will briefly describing
the process how a raw potato is changed into crunchy food snack potato chips. As shown in
the above figure there are various components or stages in transformation process.

1. Inputs
2. Quality of Input Monitored
3. Transformation Process
4. Random Disturbances
5. Quality of Output Monitored
6. Outputs
7. Feedback Mechanism

Now, each heading in more detail,

1. Inputs
The elements of Inputs utilized in transformation process are:
 Ingredients: For making potato chips we are using ingredients like Raw Potato,
Edible Vegetable oil (Palmolein oil and Rice Bran oil), Salt.
 Plant and Machinery: A good Infrastructure is required for producing chips in
large scale and to maintain hygiene. Machinery like Conveyor belts system,
Feeder, Potato peeler, Slicer, scanners, Washers, Industrial Fryer and cooling
system.
 Workers: For operating machines and supervision of the process.
 Electricity: required to run the machines and for the infrastructure.
 Administrative Staff: required to check work discipline and to look after other
clerical work.
 Packaging Material: For packing of potato chips
 Packaging Machinery: To pack potato chips in right quantity and packing
speedily.
 Managers and Production team: Is the staff required to ensure that all the
process runs smoothly and to check the quality of the product at different stages.
 Office Infrastructure: is required for the staff to log information about the
processes and a place to do other clerical work.
 Capital: Money is required for expenditures.
 Water: for washing potatoes and washing starch.
 Industrial Fryer: for frying potato chips.
 Gas Supply: Piped Natural Gas is used as a fuel by industrial fryers.
 Monitoring Equipment’s: Sensors, Scanners, Temperature sensors, Timers,
Weighing equipment’s, quality checking instruments.
2. Quality of Inputs Monitored
At this stage the quality of inputs such as ingredients which is the main component of
the whole process is monitored. Quality of the raw potatoes is checked by the staff, by
taking out sample from the batch. Quality is checked with the parameters like size,
shape, weight and temperature of the potatoes. Whole batch is processed through
scanners which identify rotten and green potatoes which are unwanted. The quality of
edible oil is also checked at the input end. Electricity supply system and machinery
are checked according to maintenance period to ensure proper working conditions.
Water quality is also been tested regularly for impurities and hardness. Everyday
workers are informed about the process and safety procedures. Machines are
monitored by workers, workers are monitored by production team and the team is
monitored by managers. Administrative staff ensures that all process are running at
optimal speed and give feedback to managers about the changes in production
capacity. And also inform about the feedback for the quality at the output end.

3. Transformation Process: It contains all the activities which take place during the
conversion of various inputs into desired output. In this process various activities are
performed in a sequence like as follows:

i. Raw potatoes fit for use, after quality check are placed on the conveyor belt
and moved towards the washing plant where the potatoes are passed through
the water jets which remove dust and impurities.
ii. Washed potatoes then went to peeler machine where the skin of the potatoes is
peeled off.
iii. Then these potatoes go to slicer machine where they are cut into thin slices
then these sliced potatoes go for washing again so that starch is removed from
the potatoes.
iv. Then washed potatoes go to drier and after drying, the potatoes go to fryers
where they are fried with edible oil for a specified time and at specific
temperature.
v. Then cooked chips go to round cooling conveyor tower so that chips
temperature can be minimized quickly so that they don’t get overcooked.
vi. Then chips are passed through camera scanner where overcooked (red/black)
chips are identified and removed from the conveyor belt.
vii. Then these chips are fed to seasoning mixture machine which sprays salt over
the chips and the seasoned chips by the conveyor went to the packaging
machine where the packaging is done.
viii. The packaging machine extract predetermined quantity of chips from the
hopper and the chips are packed in exact quantity in packing bags.
ix. These bags are filled with special air and sealed by the machine and
transferred the bag on to the conveyor.
x. The workers at packaging end put the bags into the boxes and send them to
storage facility.
4. Random Disturbances: During the transformation processes random disturbances
can be occurred like electricity failure from the grid, workers strike, unexpected
demand, machine failure, accident, sudden change in government policy, safety issue
like fire, Disturbance to due environmental calamities.

5. Quality of Output Monitored: Before Packing of chips, the chips are passed through
special cameras that identify the bad quality chips and the chip is removed from the
conveyor belt. And also after the end of packing process some bags are taken out from
the packed box and used as sample and is tested by the quality control department to
identify and ensure the product is according to the correct quality or not.

6. Output: At output a product is received which is Lay’s Potato Chips salted; customer
gets a crunchy tasty snack. Company will get revenue by selling it in the market.
Customer Satisfaction. Cheap food to have on the go. Quick snack food.

7. Feedback Mechanism: Rising sales volumes, lesser customer complaints,

productivity, rising revenue, growing market share, repeat buyers.