Process Control at Polaroid

Case Analysis Guideline

1. Discuss, the magnitude of the cost of quality in the R2 plant. And, how Rolf’s project
Greenlight is supposed to reduce the cost of quality. Especially, discuss what Rolf has been
doing in light of difference between the providing quality products by after-the-fact sample
testing and rejecting vs. controlling the production process using SPC techniques. Which of the
two processes is more representative of the Toyota Production System?
2. Construct SPC charts for weight and height. Construction, analysis, and insights from SPC
are the centerpiece of the case. Data is on EXHIBIT 3 (ATTACHED) and EXHIBIT 6
(ATTACHED.)
a. Use data on exhibit 3 to find x double bar, R bar, upper and lower control limits for x bar
charts and R chart.
b. Use data on exhibit 6 to make SPC charts (x bar and R), for weight and height.
c. Most important is to analyze the charts.
d. To analyze, in detail, you must draw separate charts (x bar and R), for weights as well as
height for each of the different shifts.
e. Give a detailed analysis of whether the process is in control. Please analyze the height, for
weight for each of the shifts here.
3. An important method for brainstorming in order to find the root cause of the problems is the
Ishikawa Diagram (ATTACHED) in order to find the cause, you have to identify all the issues
(related to people, machines, methods, and materials). Draw a use a diagram to suggest
improvements.
4. Conclusion
SUBMISSION:
Write a report in a Word document. The maximum word limit is 1500. Charts and tables
are extra. Make SPC in EXCEL. Need Word document and EXCEL DOCUMENT.