University Canada West OPMT 620 Process at polaroid-REVIEWED AND EDITED BY EXPERTS 2021

Running head: PROCESS CONTROL AT POLAROID 1




Process Control at Polaroid


University Canada West


OPMT 620: Operations Management

, PROCESS CONTROL AT POLAROID 2


Abstract


The paper explores Polaroid’s transformation from a conventional quality control method

to an operator-based statistical process control approach. The case illustrates the manufacturing

and inspection processes involved in one of Polaroid’s manufacturing plants. When faced with

numerous challenges in their operations, the company’s middle management decides to

implement a new approach called Project Greenlight to resolve operational issues. The objective

was to improve quality of its products while reducing costs. Post the new statistical concept, the

company is puzzled with a new set of challenges such as employees dealing with change. A

thorough analysis using academic literature and operation management tools was conducted for

this case study. The paper provides the history of Polaroid, situation after the Project Greenlight,

immensity of the problems, effectiveness of the past procedures, statistical process control charts,

conclusions, and recommendations to solve the short-term and long-term problems.


Keywords: Polaroid, Project Greenlight, Change management, Statistical Process Control, and,

Operations Management.

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Table of Contents
History of Polaroid..............................................................................................................5


Polaroid after the case study................................................................................................7


Case Study Summary...........................................................................................................8


The production process of the integral film at R2...........................................................8


Managing the quality and processes................................................................................8


Problems in Quality and Process Control......................................................................10


Project Greenlight..........................................................................................................11


Implementation..............................................................................................................12


Response........................................................................................................................12


Outcome.........................................................................................................................13


Issues that need to be addressed................................................................................13


What is the magnitude of the cost of quality of the problems at the R2 plant?.................14


Financial effects of the issues........................................................................................14


How effective were its past procedures for quality management?....................................14


Using the data in the exhibits, construct and analyse the appropriate SPC charts............16


Pod Weight (Grams)......................................................................................................16


Finger Height (Grams)...................................................................................................17

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SPC charts for Pod weight.............................................................................................18


SPC charts for Finger heights........................................................................................21


What conclusions should Rolfs draw?...............................................................................24


Recommendations for the short-term challenges..............................................................27


 Determine the causes of the issues and initiate a sense of urgency......................27


 Inspection at the source........................................................................................28


 Implementing Poka-Yoke.....................................................................................28


 Utilizing tools of quality management.................................................................28


 Gradual use of Microline.....................................................................................29


Recommendation for the long-term challenges.................................................................29


Guidelines for implementing change.............................................................................29


 Utilize the best method........................................................................................29


 Practice in spaced intervals..................................................................................29


 Implement drills...................................................................................................29


 The transition from the old to new.......................................................................30


 Goal Setting..........................................................................................................30