Process control at Polaroid

Chulanunt Thaiyanunt

Basing your analysis on both quantitative and qualitative tools, what

evidence is there that quality is getting better?
Pod Weight control
According to Pod Weight control chart in Appendix, the pod weight performance
variability is within the control limit (between 2.774 - 2.835), which means the
process is in control. This indicates the quality is getting better since the Pod Weight
defect rate is normal (Pod Weight measurement is a part of defect report issued by
operator, which continue 1% after Greenlight implementation) and in control,
although they reduce the number of quality control samples. However, each
average of sample of the last five shifts has decreasing trend. Therefore, Polaroid
might want to investigate the cause before the process is out of control.
Less Quality Control expense
Since quality control activities do not add value to the Polaroid camera, a company
normally wants to reduce the cost of quality control as much as possible. In Polaroid,
the quality control process itself can increase the defect rate and makes the
sampling product to be reworked. Therefore, reducing the number of samples by
implementing Greenlight saves the companys expense.
Standardize the process
Prior to the Greenlight project, the process quality at Polaroid was rely on operators
individual performance since each of them had their own mindset how to handle the
machines from their experience. The knowledge of dealing with machines belonged
to operators, not the company. The Greenlight project s provides the standard
direction, which benefits to the company since now the knowledge belongs to the
company.

Basing your analysis on both quantitative and qualitative tools, what

evidence is there that quality is getting worse?
Finger Height control
The control chart of Finger Height measurement in appendix is not as good as Pod
Weight. 20 of 45 sampling data are out of control. Moreover, the interval between
the maximum and average value and the minimum and average value is almost
equal in each shift unlike Pod Weight control chart. This means the process at
Polaroid is already stable since variant is almost the same but the operators still
tweak the machines if they feel it would improve the process quality. Finally, the
trends of control chart are different when compared by each shift. Most of data in
shift A exceeds the upper control limit while data in shift B is mostly in control and
below the lower control limit in shift C. The relation between trend and operator
shift further emphasize that the operators make adjustment to equipment on their
own.
Defect Rate reported by auditor
The defect rate reported by auditor is increased dramatically from around 1% to
10% after implementing project Greenllight. The most type of defect detected is
excess reagents (22%, according to Exhibit 5), which is not fatal since customers
would never aware of this type of defect but they still consider it as a defect. The
increase of excess reagents from 10% to 22% causes Polaroid wasting their money
than before because they have to rework more defects that do not affect the
customers satisfaction.

What recommendations would be in order to (further) improve quality?

Investigate the cause of problem
Most of samples of Finger Height measurement are out of control. Polaroid should
investigate the cause of this problem so they can prevent the same problem
occurred in the future. Also, the expense of process control quality will be reduced
after finding the cause.
Ensure the operators follow the process
The company cannot precisely measure the quality of process if they do not have
the data that reflects the actual process. In order to collect the meaningful data,

Polaroid has to ensure everyone follow the process, not adjust equipment on their
own.
Revise the types of defect
Some types of defect, such as excess reagents, are not related to customers need.
The quality controls of these measurements cause unnecessary expense for the
company. If the company can reduce the number of controlled defect types, they
will save the expense while maintain the product quality.

Appendix
Pod Weight Control Chart
Form base-line data in exhibit 3, mean and standard deviation can be calculated as
2.805 and 0.025, respectively.
Polaroid set control limit at 3 standard deviations

Upper Control Limit=+3 / numberOfSample

2.805+3(0.025)/ 6

2.835
Lower Control Limit=3 / numberOfSample
2.8053 (0.025)/ 6

2.774
By using mean, maximum and minimum value of Pod Weight sample in each shift,
the control chart of Pod Weight can be draw as the following diagram

2.880
2.860
2.840
2.820
2.800
2.780
2.760
2.740
2.720
Mean

UCL

LCL

Max

Min

Finger Height Control Chart

Form base-line data in exhibit 3, mean and standard deviation can be calculated as
2.805 and 0.025, respectively.
Polaroid set control limit at 3 standard deviations

Upper Control Limit=+3 / numberOfSample

2.805+3(0.025)/ 6
2.835

Lower Control Limit=3 / numberOfSample

2.8053 (0.025)/ 6
2.774

By using mean, maximum and minimum value of Finger Height sample in each shift,
the control chart of Finger Height can be draw as the following diagram

2.600
2.500
2.400
2.300
2.200
2.100
2.000
1.900
1.800
1.700
1.600
Mean

UCL

LCL

Max

Min

Finger Height Control Chart of Shift A

2.700
2.500
2.300
2.100
1.900
1.700
1.500
Mean

UCL

LCL

Min

Max

Min

Max

Finger Height Control Chart of Shift B

2.400
2.300
2.200
2.100
2.000
1.900
1.800
1.700
Mean

UCL

LCL

Finger Height Control Chart of Shift C

2.400
2.300
2.200
2.100
2.000
1.900
1.800
1.700
1.600
1.500
Mean

UCL

LCL

Min

Max