Quality and Process Control Procedure at R2

Quality control has responsibility for the disposition (release to market) or all
film.
Random sample is taken from finished catridge, if it contained defects in excess
of allowable limits the lot was held and further testing done. But if all of catridge
being rejected / reworked, additional sampling and testing will be take.
From 1 lot (consist of 5,000 catridge) that produce in 8 hours shif 15 sampling
taken.
Result : QC rejected just over 1% (50 catridges of 5,000) with sample avarege is
20 catridges.
Operators in each stage also do sampling in 32 random catridge (3 4 pcs per
hour) from each lot before go to QC but they did not record the data becase they
have no time to do that.
Process control in R2 initiated in late 1970s with the tracking of injection molding
equipment temperature and pressure variations.
In early 1980s, they began to measure and analyze other equipment and key
product characteristics over time to test for adherence to design specification.
Quality and Process Control Issues in 1984
In the end of 1984, R2 CQ had grown to 125 insectors who primarily sampled film
catridges as fast as possible, all day long. Sampling meant exposing film and
creating scrap and the cost of that sampled scrap alone was $540,000.
In the mid and late 1970s, R2 had un at full speed in order to keep up with
demand. Plans were laid to expand the facility significantly.
Market flattened unexpectedly in mid 1980s management recognize it and
need to cut cost at R2.
Polaroid planned to introduce a major new film to begin production in large 1985
hire more QC auditors
Early 1984, R2s quality manager and assembly production manager asked QC
engineer with a abackground in statistic to conduct a stidy of current sampling
patterns and to determine whether the amount of sampling could be reduced.
Question:
1.
Traditional / previous
approach
Fundamental principles
Role of sampling

Exposing film and

creating scrap
decreasing the number
of sampling would have
little impact on the
number of defective

Greenlight project

Role of Qc auditors

Role of operators

Maintanances
Management
Primary focus

catridges actually
reaching customers
Final responsibility for
the disposition (release
to market) of all film
Take sample 32 random
catridges out of each lot,
taking specific
measurements of
different characteristics
included the placement
of the positive on the
mask