Tortilla chip manufacturer Using operational analytics to remove a seasoning line bottleneck
Iviju helped a tortilla chip manufacturer improve plant flow through data engineering, ERP integration, and operational analytics, giving production teams a clearer way to plan seasoning and packaging work and keep orders moving
$3 million
potential cost savings per year
9% to nearly 100%
packaging schedule adherence
120 days
plan to eliminate order backlogs
- Company Tortilla chip manufacturer
- Industry Food manufacturing
- Location United States
- Engagement Production analytics and ERP integration
What needed to change
A tortilla chip manufacturer in the United States was losing time and money because a seasoning line bottleneck was slowing packaging. Chip batches moved from frying to seasoning and then into final packaging for different product sizes and flavor varieties
The seasoning line was using 30 separate ERP reports to plan work, and teams often chose the next batch based on what was closest rather than what packaging needed most. Planning accuracy had dropped to 47% and only about 9% of orders were being packed on schedule
How Iviju delivered
Iviju started by separating the problem into planning and sequencing so the plant could address the bottleneck in a structured way. For planning, we transformed data from finished seasoned inventory, current packaging demand, and upstream work in progress to identify which batches needed to run first
For sequencing, we applied algorithms that optimized the order of batches moving through the seasoning line based on factors such as time of day, shift patterns, cycle time, and packaging production rate. We also quantified the financial impact of delays and mapped a practical plan to remove backlogs and support a more automated workflow
Implementation specifics
We broke the work into planning and sequencing, transformed data from seasoned inventory, packaging demand, and upstream work in progress, then applied algorithms that prioritized the right batches and optimized the seasoning line sequence by shift, cycle time, and packaging rate
What changed after delivery
With a clearer planning model and a better sequence for seasoning operations, the manufacturer had a workable path to move batches to packaging when they were actually needed. The analysis gave plant leaders a concrete view of where losses were occurring and what operational changes would produce the biggest return
The work identified up to $3 million in yearly savings, a path to raise packaging schedule adherence from 9% to nearly 100%, an increase in seasoning line planning accuracy from 47% to almost 100%, and a 120 day plan to eliminate order backlogs
- Packaging schedule adherence improved from 9% to nearly 100%
- Seasoning line planning accuracy increased from 47% to almost 100%
- A 120 day plan was defined to eliminate order backlogs
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