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 company’s 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 customer’s
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 customer’s 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 = 𝜇 + 3𝜌/√𝑛𝑢𝑚𝑏𝑒𝑟𝑂𝑓𝑆𝑎𝑚𝑝𝑙𝑒

= 2.805 + 3(0.025)/√6

= 2.835

𝐿𝑜𝑤𝑒𝑟 𝐶𝑜𝑛𝑡𝑟𝑜𝑙 𝐿𝑖𝑚𝑖𝑡 = 𝜇 − 3𝜌/ √𝑛𝑢𝑚𝑏𝑒𝑟𝑂𝑓𝑆𝑎𝑚𝑝𝑙𝑒

= 2.805 − 3(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 = 𝜇 + 3𝜌/√𝑛𝑢𝑚𝑏𝑒𝑟𝑂𝑓𝑆𝑎𝑚𝑝𝑙𝑒

= 2.805 + 3(0.025)/√6

= 2.835

𝐿𝑜𝑤𝑒𝑟 𝐶𝑜𝑛𝑡𝑟𝑜𝑙 𝐿𝑖𝑚𝑖𝑡 = 𝜇 − 3𝜌/ √𝑛𝑢𝑚𝑏𝑒𝑟𝑂𝑓𝑆𝑎𝑚𝑝𝑙𝑒

= 2.805 − 3(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

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 Min Max

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