Sahale Snacks, Inc. was founded in Seattle 2003 by two friends that set out to create a natural and healthy snack that tasted great. Sahale Snacks is dedicated to helping people “Snack Better™” by offering consumers convenient, delightful, healthy snacks. Roth Gonzales, Process Improvement Manager at Sahale Snacks, demonstrated that same passion in the production of their products when he joined Sahale Snacks. “Because I had used Synergy 1000 at a previous company, I recommended purchasing the Synergy 1000 Statistical Process Control (SPC) software when I came on board,” said Gonzales. “I could see where the Synergy 1000 SPC software could assist us to increase our productivity and avoid being out-of-specification.” Roth was confident he could attain his ROI Using Synergy 1000 SPC Software.
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Prior to that time, all the data collection was performed by hand on paper by the machine operators. Depending upon the line, they could have anywhere from 2 to 4 checks an hour. This meant the operators had to go away from their machines and hand enter the data. With 3 production lines, Gonzales found that machine operators were spending 1/3rd of their time dedicated to quality. The data then had to be entered into Excel to perform the statistics. “Now they stay at their machines and get real-time information. With that comes less waste and less machine downtime,” said Gonzales. “Previously, if the machine was out-of-specifications, it wasn’t being caught until after the fact. We would have to reweigh the product and repackage the product. Now it doesn’t happen at all or it has decreased significantly.” Also, Sahale had no real-time reporting or alerts.
“Our expected Return On Investment for purchasing Synergy was $16,000. We met our expectations.”
— Roth Gonzales, Process Improvement Manager at Sahale Snacks
Because Synergy 1000 is real-time, Sahale expected to see a reduction in line downtimes. They also estimated they could save 7 machine operators 1/3rd of their day, and 2 Quality assurance personnel about an hour a day. “Our expected Return On Investment (ROI) for purchasing Synergy was $16,000,” said Gonzales. “We met our expectations.”
One of the ways that the Synergy 1000 helps Sahale save money is by reducing the amount of overpack. Overpack is when Sahale would put in more than what is printed on the pouch. “To overpack is to give away the product,” Gonzales explained. “Previously, we would review by the week. Now we can use real-time measurements and make immediate adjustments.”
Because they now have access to real-time information, Sahale is able to make justifications on how to improve their lines as well. Sahale used the data generated from Synergy 1000 to justify the purchase of a new, more sensitive scale. “Our ROI for the new scale is $61,000,” said Gonzales. “While we have always collected data the frequency and accuracy have greatly improved. The software helped us clarify the need and justify the purchase.”
Synergy 1000 can also help with new product development. Sahale wanted to test out a new fruit and nut mix and see if their mixing machine was mixing the proper percentage of each of the four fruits. “We wanted to see how well the mixing equipment was working to create these new products. The data from Synergy 1000 justified that our mixing equipment was sufficient to mix this new product,” remarked Gonzales.