Sampling 32 random cartridges out of each lot

Reject as little as one cartridge out of a lot Have no standard quality knowledge
Production Operators
Not record the data that they collected Have no time to take all the samples

Operators free to change the equipment setting

1972 Inroduce Polaroid's SX 70 Camera
Gathering data and performing rough analysis
Process engineering technicians 1980 Used mainly by professional photographers & industrial/technical users
Measuring & analyzing other equipment & key product characteristics Traditional Operation 1981 Reducing machine variability, baselining
Final responsibility to all film that release in market QC Department
1983 Traditional process control measures & analyses
No one was responsible for the overall production process
History Conduct a study of current sampling patterns
QC was not testing for the types of defects that consumers noticed
Head up Project Greenlight
Operators often did not record defective sample Problem 1984
R2 QC had grown to 125 inspectors
Each cartridge codes were seldom checked
Pressure to limit and reduce costs
The sampling process was imprecise and often inaccurate
1985 Roll up Project Greenlight

Manufacture instant film

R1 Manufactured peel-apart film
Reduce quality monitoring cost
Objectives Manufactured integral film
Processed Control at Polaroid
Maintain & improve product quality
Materials
Processes in control & produce more consistent quality
Labor
Implement operator-based statistical process control Cost
Administrative overhead
Production operators would be given the process control tools Plan
Fixed costs allocation
R2
Quality control auditors would concentrate on training & operationalizing specifications
Negative film
Training operators and executing the implementation phase
Reagent
Determined standard settings Input
Implementation Product Polaroid's Integral Film Batteries
Operators required to shut down their equipment
Plastic sheets
Determine and adhere to standardized "best practice" procedures Operations
Project Greenlight Pods
Determining the proper centerline and range of values
Plastic cartridges
General dissatisfaction in first few months Problems
Output Sheet metal springs
Different types and proportions of defects between auditors and operators
Plastic & caps internally
Reported defective rate from the operators had dropped
Film cartidges
Reported defective rate from the central process auditors had climbed Results
R3 Administrative offices
Management can analyze the accurate representation of the true defects in the process
R4 Produced battery
Develop more systematic and automated methods

Convince others and customers that there is no quality problem

Must sucessfully implement Project Greenlight

Challenges Going Forward
How should they incorporate consumer research regarding customer specifications into the process control system?

What could they do to ease the transition for maintenance, engineering, and quality control from the old concept to the new?

What could they do in the future to keep people focused on improving quality once defect rates dropped significantly below 1%?
 POLAROID

Question :
1. How should they incorporate consumer research regarding customer specifications into the process control system?
Answer :
Company must reduce the variability of customer specification then group them into good customer spesifications that allowed in
range. Then company must define the upper and lower specification limit and create or develop the product that the quality is in the
range.
Company must measure the process capability and determine the good standard process to create good quality products, create
customer value, and reduce the defect products.

2. What could they do to ease the transition for maintenance, engineering, and quality control from the old concept to the new?
Answer :
Project Greenlight team must be socialize the program to all BOD and to all employees and make commitment with them to succeed
the program. With the top management, they must collaborated to fix position who responsible for each production process. They
must determine standard operation and standard maintenace, operators and SQC must enhanced the knowledge about the good
standard products, and marketing also research and development unit always do the market and customer research.

3. What could they do in the future to keep people focused on improving quality once defect rates dropped significantly below 1%?
Answer :
Research and development unit always analyze and research the market and customers, so company knows what customer wants
from the products, whats the defects about the product after customers used it, and who is the company competitor. From the
external information, we can use it to develop our product and always creating innovation product so company can expand the
market. In internal company, planning unit or related unit also must be innovative so the production process become more effective
and efficient.