INTRODUCTION

In 1948, Polaroid made a remarkable breakthrough in consumer photography. Instead of the

traditional handheld camera that required developing a film canister, Polaroid created instant
photographywithoutsacrificingquality.Twobasictypesoffilmwereavailabletoconsumers:peelapart
and integral. Both types produced images through a shutter projecting onto a negative that when
removed, produced an image through a chemical agent that was activated. Integral film was
introducedinconjunctionwiththePolaroidSX70in1972.Thismodelincludedacartridgethatheldten
frames(piecesoffilm)andwasselfdevelopingandselftiming.Theintegralfilmwasproducedinfour
buildings, known as R1, R2, R3, and R4. R1 manufactured the peelapart film, R2 manufactured the
integralfilm,R3housedtheadministrativeoffices,andR4producedthebatteriesrequiredfortheflash
andoperationofthecamera.ThispaperwillfocusonthemanufacturingprocessoftheR2plant,where
900employeesworkedthree/eighthourshifts,fivedaysaweek.
In1985,anoperatorbasedstatisticalprocesscontrolmethodcalledProjectGreenlightwasintroduced
totheR2plantinanefforttocutcostswhilemaintainingorimprovingquality.Thisprojectrequireda
fundamental shift in manufacturing philosophy and employee roles. Instead of a focus on maximizing
production and machine utilization, Greenlight instead emphasized reducing waste through controls
andstandardization.
Theinitialresultsoftheprojectweresurprising.QualityControl(QC)auditorsreporteddefectrates10
timeshigherthanthepreviouslevel,butProductionOperatorsreportedathalfoftheirpreviousrate.It
isthegoalofthispapertodemonstratethattheGreenlightProjectdidnotsacrificequalityinorderto
savemoney,butinsteadimplementedaprocesscontrolsystemthatwasgroundedinsoundstatistical
andoperationalfundamentsthatwouldprovebeneficialtothebottomlineofthecompany.

ANALYSIS

OperationsatR2
TheplantR2producedsheetmetalsprings,pods,plasticcartridges,andplasticendcapsinternally,and
then assembled everything into film cartridges. R2 had three floors: On the first floor, Spring
Production, Pod Production, and Packaging were located, while on both the second and third floors,
CartridgeProductionandAssemblyareaswerelocated.Theplantoperatedwiththree,eighthourshifts
perday.Eachshiftproducedlotsof5,000cartridges,allofwhichweresubjecttoinspection.
PolaroidsIntegralFilmProductionProcessispresentedbelow(detailedimageinExhibit1).

NegativeFilm
Reagent
Batteries
Plasticreceivingsheets

Flowchart

Supplies

Supplies

Supplies

Supplies

Metal
Springs

Reagent
Pods

Cartridges
outershell

Supplies

Checkfortension
ofthespring

Checkforamountof
reagentinthepod
DarkRoom
Prep

Checkforpositive
placementonthemask
DarkRoom
Assembly

NegativeSpring
PodEndcap
Battery Ind.framing

First
Sampling

Second
Sampling

EndofSampling
(firstsamplesaredestroyed)
Packaging

Shipping

Third
Sampling

Lotrejected

QualityandProcessControlProceduresatR2
ThequalityandprocesscontrolatR2wasmanagedbytwoseparategroups;ProductionOperatorsand
QualityControlauditors.
Production Operators were required to gather information taken from specific measurements of the
cartridgesandprovideinputsaboutthefunctioningoftheequipment.Operatorsinspectedthecartridge
atthreestagesoftheprocess:
1. Springproduction:wherespringtensionwastested.
2. Podproduction:wheretheamountofreagentinthepodsistested.
3. PriortoDarkRoomassembly:wheretheplacementofpositiveonthemaskischecked.
Given the required number of cartridges to be assembled in R2, Production Operators focused on
maximizing total machine utilization as opposed to maximizing the efficiency of the entire process.
Operatorsateachstageoftheprocesssampled32randomcartridgesoutofeachlotcontaining5,000
cartridges. In 1984, approximately 1% of production was rejected. There were occasions when
Production Operators allowed questionable samples to advance in the process because they did not
havetimetotakeallthesamplescalledforbytheprocedure.Additionally,theybelievedthatifthere
wasinfactaproblemwiththesample,itwouldbecaughtbyQualityControlauditorsatalaterstage.
QualityControlauditorswerestagedattheendoftheassemblyprocess,priortopackaging,wherethey
had final disposition of all film sent to customers. Quality Control auditors randomly sampled 15
finishedcartridgesoutofeverylot,andultimatelyrejectedapproximately1%ofallcartridges(in1984).
Theauditorscouldmakethefollowingdecisionsbasedontheresultsoftheirinspection:
1. Ifthereweredefectsinthesampledcartridges,thelotthatcontainedthesampleswasheldand
further testingwasconducted. Additionalsamplingwould determineifrejectionorreworking
wasrequired.
2. Ifexcessivedefectswerefoundinthelot,thenthenumberofunitssampledinthenextlotwas
increased.
Apart from the Production Operators and Quality Control auditors, Process Engineering technicians
wereresponsibleforgatheringdataandperformingroughanalyses.Theyalsomeasuredandanalyzed
equipment and key product characteristics over time, to test for adherence to design specifications.
Process engineers were responsible for materials, while mechanical engineers were responsible for
equipment.
SpearheadingthepursuitofefficiencyintheproductionprocesswastheintroductionofBaseliningat
Polaroid. Under this outline, maintenance and mechanical engineers were responsible for making the
machines operate in order for them to meet target specifications, instead of just increasing the
utilizationofthemachine,makingitgofaster.

ImplicationsoftheProcess
Mostofthetime,thesamplingprocessrequiredexposingthefilmwithincartridgesandcreatingscrap.
Basedoncaseinformation,in1984,atotalof$3.28millionwaslostinscrapduetothefollowing:
1. ThecostofscrapfromQualityControlwas$540,000.
2. ThecostofscrapfromProductionOperatorswas$740,000.
3. Therejectionsduetoexcessdefectsincludedanother$2,000,000.
It was found that, the act of testing for defects can actually increase the defective rate of the
cartridges.Iftherewere excessdefectsfoundin thefirstbatch of15cartridges,anadditionalsample
fromthesamelotwouldbetaken.Iftheinspectedcartridgespassed,theyweresentbacktoproduction
to be repackaged. The samples were put back into the inspection queue and were subject to further
randomsampling.Theprocessofhandling,unpacking,andrepackingdamagedsomeofthecartridges,
whichcausedthedefectratetoincrease.
Therewereseveralotherissuesthatdecreasedtheeffectivenessoftheoriginalprocess.Amongthem,
weretheactionsmadebymanyoftheProductionOperatorsandQualityControlauditors:

Production Operators salted boxes. Dispersed questionable batches across lots to dilute
theirchancesoffailinganinspection.
ProductionOperatorsletslidequestionablesampleswiththeexpectationthatQCauditors
wouldcatchthemandmakeafinaldecision.
QualityControldidnttestforsomeofthedefectsthatcostumersnoticedandcomplained
about,butwererejectingfilmbasedonsomedefectsthatcustomersdeemedunimportant,
such as excess reagent defect, where Quality Control would check if any excess reagent
wasleakingoutofthetopoftheframe.
QualityControlusedonlyperfectcamerasfortesting,potentiallymissingqualityissuesthat
arosefromfilminteractionswithimperfectcamerasthatcustomersaremorelikelytouse.

Excessivescrap,duplicationofeffort,andpoormachineutilizationledtoinefficienciesandwasteduring
theproductionprocessthatPolaroidinitiallycreated.
MagnitudeoftheCostofQualityProblemsatR2
Materialcost:Sincesamplingresultedinalotofscrap,thecostofthescrapisevaluatedasfollows.
TypeofMaterialCost
CostofScrapfromQualityControl
CostofScrapfromProductionOperator
CostduetoRejectionofFinishedProduct
TotalMaterialCost(SumofallScrap)

$ 540,000
$ 740,000
$ 2,000,000
$ 3,280,000

(Thenumbersabovearereferencedfrompage4oftheoriginalcase).

LaborCost
QualityControlAuditorsCost:Givenatotalof125QualityControlauditorsemployed,assumingeach
waspaidawageof$40,000peryear,thenatotalof$5million(125auditors*$40,000individualwage)
wasspentontheQualityControlauditorstosample.
LaborCostforQualityControl
WageforeachQualityControlauditor
NumberofQCauditors
TotalwagespaidtoQualityControlauditors

$ 40,000
125
$ 5,000,000

(Thenumbersaboveweregiveninthecasequestions).
Process Operators Cost: There are 900 employees working in R2, of which 125 are Quality Control
auditors, leaving 775 employees not involved in QC. From these 775, it is assumed that one third is
involved in sampling, which yields a total of 250 operators. Assuming that these operators have the
samewagesasQCauditors,butspendonlyonequarteroftheirshifttakingsamples,theoperatorcostis
calculatedasfollows.
LaborCostforProcessOperators(part1)
TotalnumberofPolaroidEmployeesinR2
No.ofEmployeesotherthanQC
Assumingthatonethirdofemployeesare
involvedinsampling
Assumingthatwagespaidarethesamefor
operatorsandthequalitycontrolauditors

Calculation
giveninthecase
=900125
=775/3approx.

Result
900
775
250

=250*$40,000 $10,000,000

From the information presented above, it is assumed that Process Operators dont spend all their
working hours doing sampling, and therefore the actual cost of sampling from the operators would
result in a fraction of their entire salary. For the purposes of this paper, it is assumed that Process
Operatorsspendoftheirshift(8hourshift/4=2hours)onsampling,thus,thesamefractionoftheir
salarywouldrepresenttheactualcostofsamplingbyoperators.Aspresentedinthefollowingtable:
LaborCostforProcessOperators(part2)
TheCostofSamplingbyOperators

Calculation
Result
=$10,000,000/4 $2,500,000

Fromthedatacalculatedabove,thetotalcostofthewagesandscrapderivedfromsamplingis:
CostofLabor+MaterialfromSampling
TotalMaterialCost(SumofallScrap)
TotalwagespaidtoQualityControlauditors
ThecostofsamplingbyOperators
TotalCostSampling(Labor+Material)

$ 3,280,000
$ 5,000,000
$ 2,500,000
$ 10,780,000

AssessingPolaroids19801984financialinformation(Exhibit2),theoverallcostofgoodssoldis$735M.
Basedoninformationgiveninthecase,theConsumerPhotographydivision(Peelapart+Integral)was
responsiblefor40%ofPolaroidstotalrevenues;consideringthesamepercentageforCOGS,theCOGS
fortheConsumerPhotographydivisionis40%of$735M,or$294M.Giventhat,atthatpointintime,
most of the Consumer Photography in the company was Integral, a total of $265M is considered for
IntegralCOGS(assuming90%ofConsumerPhotographyCOGS,or$294M*90%).
If,aspresentedabove,$10.78Mislostinscrapandrejections,then the percentageoftheplantlevel
COGS is calculated as: $10.78M (Total Cost Sampling including Labor and Material) / $265M (Integral
COGS)=3.9%.Thisindicatesthat3.9%oftheIntegralConsumerPhotographyCOGSisduetosampling.
Therefore, any reduction in the cost involved with sampling will add to the profits of the R2 business
unit.
ProjectGreenlight
Numerical analysis, conducted by a QC engineer with a background in statistics, indicated that
decreasingsamplingwouldnothaveasignificanteffectonthenumberofdefectivecartridges.Itwas
determined that reducing the production sampling by 50% would only increase the amount of units
released to customers to .03% of production. Therefore, reducing the sampling would reduce costs
withoutsignificantlyaffectingthedefectiveoutput.
BudRolfsheadedateamtoinvestigatewaystoreducethequalitymonitoringcostswhilemaintaining
or improving the product quality. This team designed and implemented a project called Greenlight,
whichinvestigatedwaystoimprovethequalitycontrolprocessbeyondsimplyreducingthenumberof
samples taken. Greenlight incorporated a strategy to implement operator based statistical process
controlusingthestatisticaltoolsforcontinuallymonitorandanalyzetheprocess.Thestrategyincluded
thefollowingkeyelements:
1. Adoptstatisticalprocesscontrolprinciplestoconsistentlymeetspecificationlimits.
2. Operators would be given relevant process control tools to perform sampling and make
decisions,includingtheresponsibilitytotakemeasurementsandrecordthemonXandRcharts.
3. Quality Control auditors were in charge of training Production Operators and standardize
operatingspecificationsonmachineryandnewproducts.AuditorsalsotrainedtheProduction
Operators in performing control limit calculations, and assisted in the calculation of baseline
dataforpodweightandfingerheight.
Further,thefollowingruleshavebeendevelopedbytheteamtodetermineiftheprocessisincontrol.
1. During sampling, if any of the observations were outside of the control limits, the protocol
dictatedtoimmediatelyshutdownthemachineandcallforamaintenancetechniciantoclean,
recalibrate,andrestartthemachine.
2. Ifconsistentupwardordownwardtrendswereobserved,orifeightconsecutivemeanvalues
fellintheupperorlowerzone,maintenancewastobecalledtoinvestigate.

Todeterminethecontrollimits,baselinedatawascollectedusingsamplingtechniques.Thecenterline
andthecontrollimitswerefound,andwereusedtocreaterequiredproceduresforoperators.Standard
settingsofthemachinesweredetermined,andunderthesesettings,operatorswererequiredtoshut
downtheirmachinesandcallformaintenancewhentheprocesswasoutofcontrol.Thisiscounterto
previoustechniquesthatoperatorsusedtotweakindividualmachinestomaximizequantityoutput.
StatisticalProcessControlCharts
By utilizing the baseline data provided in the case(Exhibit 3), the control limits for pod weight and
fingerheightwerecalculatedasdescribedbelow.
The mean of the observations in each sample was calculated by using the average equation to
determineX.
PodWeight(grams)
Day
20July
21July
22July
23July
24July
27July
28July
29July
30July
31July

1
2.792
2.774
2.797
2.819
2.754
2.784
2.844
2.806
2.843
2.816

2
2.810
2.783
2.790
2.787
2.793
2.781
2.799
2.786
2.766
2.790

SampleNumber:
3
4
2.777 2.799
2.799 2.820
2.785 2.795
2.809 2.862
2.820 2.846
2.733 2.801
2.781 2.802
2.836 2.815
2.795 2.778
2.823 2.802

5
2.803
2.812
2.866
2.823
2.823
2.823
2.820
2.836
2.835
2.780

6
2.788
2.807
2.826
2.816
2.807
2.844
2.813
2.808
2.783
2.804
Mean(x)

Mean
2.795
2.799
2.810
2.819
2.807
2.794
2.810
2.815
2.800
2.803
2.805

2
2.158
2.256
2.166
2.171
2.032
2.108
2.302
2.189
2.128
1.990

SampleNumber:
3
4
2.049 1.959
2.099 2.269
1.955 2.125
2.068 2.143
2.032 1.955
2.105 2.037
2.019 2.154
1.970 2.067
1.976 2.228
1.863 2.183

5
2.107
2.193
1.988
1.979
2.018
1.957
2.104
2.088
2.036
2.020

6
1.875
2.193
2.009
2.278
2.007
1.881
1.830
1.903
1.949
1.889
Mean(x)

Mean
2.028
2.141
2.041
2.136
2.035
2.017
2.058
2.066
2.047
2.034
2.060

FingerHeight(mm)
Day
20July
21July
22July
23July
24July
27July
28July
29July
30July
31July

1
2.021
1.836
2.004
2.177
2.167
2.016
1.939
2.179
1.962
2.260

The range was determined by subtracting the minimum value from the maximum value of each
observation.Basedonthisdata,theaverageoftherange,R(Meanrange)wasfound.

PodWeight(grams)
Day
20July
21July
22July
23July
24July
27July
28July
29July
30July
31July

1
2.792
2.774
2.797
2.819
2.754
2.784
2.844
2.806
2.843
2.816

2
2.810
2.783
2.790
2.787
2.793
2.781
2.799
2.786
2.766
2.790

SampleNumber:
3
4
2.777 2.799
2.799 2.820
2.785 2.795
2.809 2.862
2.820 2.846
2.733 2.801
2.781 2.802
2.836 2.815
2.795 2.778
2.823 2.802

5
2.803
2.812
2.866
2.823
2.823
2.823
2.820
2.836
2.835
2.780

6
Maxvalue MinValue
2.788
2.81
2.777
2.807
2.82
2.774
2.826
2.866
2.785
2.816
2.862
2.787
2.807
2.846
2.754
2.844
2.844
2.733
2.813
2.844
2.781
2.808
2.836
2.786
2.783
2.843
2.766
2.804
2.823
2.78
Mean(x)
Meanrange

Range
0.033
0.046
0.081
0.075
0.092
0.111
0.063
0.05
0.077
0.043
0.0671

2
2.158
2.256
2.166
2.171
2.032
2.108
2.302
2.189
2.128
1.990

SampleNumber:
3
4
2.049 1.959
2.099 2.269
1.955 2.125
2.068 2.143
2.032 1.955
2.105 2.037
2.019 2.154
1.970 2.067
1.976 2.228
1.863 2.183

5
2.107
2.193
1.988
1.979
2.018
1.957
2.104
2.088
2.036
2.020

6
Maxvalue MinValue
1.875
2.158
1.875
2.193
2.269
1.836
2.009
2.166
1.955
2.278
2.278
1.979
2.007
2.167
1.955
1.881
2.108
1.881
1.830
2.302
1.83
1.903
2.189
1.903
1.949
2.228
1.949
1.889
2.26
1.863
Mean(x)
Meanrange

Range
0.283
0.433
0.211
0.299
0.212
0.227
0.472
0.286
0.279
0.397
0.3099

FingerHeight(mm)
Day
20July
21July
22July
23July
24July
27July
28July
29July
30July
31July

1
2.021
1.836
2.004
2.177
2.167
2.016
1.939
2.179
1.962
2.260

After determining the above information, critical statistical calculations have been performed. These
includetheuppercontrollimit(UCL)andthelowercontrollimit(LCL).
TheUCLandLCLforXchartwerefoundwiththefollowingequations:
PodWeight(grams)
UCL=X+(A2*R)
(2.805+(0.48*0.0671)=2.837

LCL=X(A2*R)
(2.805(0.48*0.0671)=2.773

FingerHeight(mm)
UCL=X+(A2*R)
(2.060+(0.48*0.3099)=2.209

LCL=X(A2*R)
(2.060(0.48*0.3099)=1.912
TheUCLandtheLCLforRChartwerefoundwiththefollowingequations:
PodWeight(grams)

UCL=D4*R
(2*0.067)=0.134
LCL=D3*R
(0*0.067)=0

FingerHeight(mm)

UCL=D4*R
(2*0.310)=0.620
LCL=D3*R
(0*0.310)=0

ThevaluesofA2,D4andD3wereobtainedfromtheE.L.GrantandR.S.Leavenworthtable,asummaryof
whichispresentedbelow(FulltableinExhibit4).
E.L.GrantandR.S.Leavenworthtable
Numberofobservationsineachsample
FactorforXbarChart
FactorforRChartLCL

n
A2
D3

6
0.48
0

FactorforRChartUCL

D4

ComprehensivetablewithUCLandLCLcalculationsforXandRchartsinExhibit3.
With the information derived from the baseline data, the X and R charts were created using the
measurementstakenbytheoperators.Themeansandtherangesforeachsamplewerecalculatedin
thesamewayasbaselinedata.TheXandtheRcalculationsoftheentiregroupofmeasurementsare
shownonExhibit5.TheXandtheRcalculationsofthemeasurementsshiftwiseareshownonExhibit6.

Todetermineiftheprocessisincontrol,inadditiontotherulesgiveninthecase(presentedonpage6),
thefollowingpointsshouldalsobeconsidered:
1. If there are any points near to the upper or lower control limit, then investigation of the
processmustbedone.
2. Ifanytrendineitherdirectionofthemeansisidentified,theprocessmustbeinvestigated.
3. Ifthereisanysuddenchangeinthelevelorerraticbehaviormustbeinvestigated.
PodMakingProcess
SincethecontrollimitsontheXchartarederivedfromtheaveragerange,Rchartsmustbeobserved
first. As shown in the R chart for all the shifts combined (Figure 1), the variation of the pod making
processiswithinthecontrollimits.

PodWeightRAllShifts
0.160
0.140

Range

0.120
0.100

Range

0.080

LCL

0.060

CL

0.040

UCL

0.020
0.000
1

11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45

Figure1

To further understand the stability of the process, the X chart in Figure 2 is observed. The values are
within the control limits. However, there is a trend in the last few shifts towards the LCL. Hence the
processistobeverifiedbeforeitstartsproducinganydefects.

PodWeightXAllShifts
2.860
2.840

Mean

2.820
Mean

2.800

LCL
CL

2.780

UCL

2.760
2.740
1

11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45

Figure2

Additionally,theXandRchartsareplottedforeachoftheshifts.Figures3,4and5presenttheRcharts
forshiftsA,BandCrespectively.AfewvaluesinshiftAarelocatedinthelowerrange,however,mostof
thevaluesareneartheR.TheprocessvariationseemstobeincontrolinshiftsBandC.

PodWeightRChartAShift
0.160
0.140

Range

0.120
0.100
0.080

Range

0.060

LCL

0.040

CL

0.020

UCL

21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

3August

0.000

Figure3

Figure5

21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

3August

Range

21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

3August

Range

PodWeightRChartBShift

0.160

0.140

0.120

0.100

0.080
Range

0.060
LCL

0.040
CL

0.020
UCL

0.000

Figure4

PodWeightRChartShiftC

0.160

0.140

0.120

0.100

0.080
Range

0.060
LCL

0.040
CL

0.020
UCL

0.000

Continuing with the X charts of Pod weight for each shift, it can be determined that the values are
within the control limits, but the process has to be inspected as the trend is towards the LCL. Refer
Figures6,7and8forXchartsofPodweightinShiftA,BandCrespectively.

PodWeightXAShift
2.860
2.840

Mean

2.820
Mean

2.800

LCL

2.780

CL

2.760

UCL

21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

3August

2.740

Figure6

PodWeightXBShift
2.860
2.840

Mean

2.820
Mean

2.800

LCL

2.780

CL

2.760

UCL

21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

3August

2.740

Figure7

PodWeightXCShift
2.860
2.840

Mean

2.820
Mean

2.800

LCL

2.780

CL

2.760

UCL

21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

3August

2.740

Figure8

FingerHeightProcess
ItcanbedeterminedthroughtheRChartofalltheshiftstogetherinFigure9thattheprocessvariations
arewithinthecontrollimits.

FingerHeightRchartAllShifts
0.690
0.590

Range

0.490
Range

0.390

LCL

0.290

CL

0.190

UCL

0.090
0.010
1

9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45

Figure9

FromtheXChartinFigure10,itcanbeunderstoodthatmanyvaluesareoutofthecontrollimitsand
theprocesshastobestopped,forthemachinestobecleanedandrecalibrated.

FingerHeightXAllShifts
2.400
2.300

Mean

2.200
Mean

2.100

LCL

2.000

CL

1.900

UCL

1.800
1.700
1

9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45

Figure10

LookingattheRchartsofindividualshifts,therangesareinthelowerregionforshiftB.Thiscouldbea
concernwiththeoperatorsinthisshift,astheymaynotbetakingtheobservationsproperly.Referto
Figure11,12and13forRchartsofshiftsA,BandCrespectively.

FingerHeightRChartShiftA
0.69
0.59

0.39

Range

0.29

LCL

0.19

CL

0.09

UCL

21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

0.01
3August

Range

0.49

Figure11

0.10

Figure13
21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

3August

Range

21August

20August

19August

18August

17August

14August

13August

12August

11August

10August

7August

6August

5August

4August

3August

Range

FingerHeightRChartShiftB

0.69

0.59

0.49

0.39

0.29
Range

LCL

0.19
CL

0.09
UCL

0.01

Figure12

FingerHeightRChartShiftC

0.70

0.60

0.50

0.40

0.30
Range

0.20
LCL

CL

0.10

0.00
UCL

TheXchartsforeachshiftarepresentedinthefiguresbelow(14,15and16),wheremanypointsare
notwithinthecontrollimits.AspertheprojectGreenlightrules,theoperatormustimmediatelyshut
down the machine and call for maintenance to clean, recalibrate and restart the machine. Since the
problemispersisting,managementshouldbrainstormandconductdesignedexperimentstofindthose
processelementsthatcontributetosporadicchangesinprocesslocation.Presently,theprocessisnot
incontrolanditisnotpossibletodeterminetheoutcomeofanunstableprocess.

Mean

FingerHeightXShiftA
2.40
2.35
2.30
2.25
2.20
2.15
2.10
2.05
2.00
1.95
1.90

mean
LCL
CL
UCL

Figure14

FingerHeightXShiftB
2.32
2.22

Mean

2.12
mean

2.02

LCL

1.92

CL

1.82

UCL

1.72

Figure15

FingerHeightXShiftC
2.31
2.21

Mean

2.11
mean

2.01

LCL

1.91

CL

1.81

UCL

1.71

Figure16

Capabilityoftheprocess
Theprocesslimitsforthepodweightarefoundinordertodeterminetheconsistencyoftheprocess.
Thevaluesobservedarewithinthecontrollimitsofthreestandarddeviations.However,asperdesign,
thecontrollimitsareslightlygreaterthanthespecificationlimits.Thespecificationlimitsaretherange
ofvaluesthatsatisfytheintendeduseoftheproduct,normallygivenbythecustomer.Giventhatthis
information is not provided, it is possible that some of the items produced do not meet the
specifications.
The process is capable only when the mean and standard deviation are such that the upper and the
lowercontrollimitsareacceptablerelativetotheupperandlowerspecificationlimits.Giventhelackof
informationmentionedabove,thecapabilityoftheprocesscannotbedetermined.

AssessmentofProjectGreenlight
Project Greenlight started with two main goals: to cut costs and improve product quality through
statisticalprocesscontrol.Polaroiddeterminedthatreducingsamplingwouldhavelittlenegativeeffect
onproductquality,butconsiderablysaveincosts.
Toimprovequality,ProjectGreenlightgavecontrolandfinalresponsibilitytoProductionOperatorsat
several stages in the production process. This allowed for accurate measurements and quality control
throughouttheprocess.

Greenlight provided the potential to identify unstable manufacturing processes and develop best
practices for maintenance and mechanical engineers. The restructured procedures allowed
managementtosavemoneybyreducingQCpersonnel.
However,noteverythingwentaccordingtoplanafterGreenlightwasintroduced.Reporteddefectrates
indicateaconsiderableriseindefectsuncoveredbyQualityControlauditors.Whilethereporteddefect
ratesfromProductionOperatorsdroppedfrom1%to.5%,thedefectratereportedbyQualityControl
auditors increased from 1% to over 10%. One possible explanation for the increase is that the finger
heightprocessisnotstable,causingQualityControlauditors,butnotProductionOperators,toobserve
defectswhosevaluesfalloutsideofthecontrollimits.
AmorelikelycauseofthedefectratediscrepancyisthattheQualityControlauditorsareoverzealously
findingfaultsinthecartridgesinanattempttoestablishtheirvalueasemployeesandsavetheirjobs.
AdditionalinformationisrequiredtodetermineifthemanytypesofdefectsfoundbyQualityControl
auditors are relevant to the customer. It is also possible that previous unobserved defects are being
observed now, because of the statistical process control that Greenlight entails, and therefore, the
amountofactualdefectsmaynothavechangedandqualitymaynothavebeenimpaired.

RECOMMENDATIONS
ItisrecommendedthatProjectGreenlightbeimplementedasdesigned.Themostimportantstepthat
RolfsmustdotoallowGreenlighttosucceed,iseducateemployeesontheimportanceandbenefitsof
thenewstatisticalcontrolprocess.Employeesarenaturallyskepticalaboutchangesinthestatusquo,
butaconcertedeffortbymanagementtoembracethechangeisvitaltothesuccessoftheprogram.
Appropriatetrainingmusttakeplacetoprepareallemployeesfortheirnewrolesandresponsibilities.
An incentive program tied to collective and individual performance should be considered to motivate
employeesandimprovemorale.
Lastly,acomprehensivelistofdefectsthatarerelevanttocustomersshouldbegeneratedtoevaluate
production.Alldefectsnotonthelistshouldbeignored.

Exhibit1

Exhib
it 1

(cont.)

Exhibit3

PodWeight(grams)
Day
20July
21July
22July
23July
24July
27July
28July
29July
30July
31July

1
2.792
2.774
2.797
2.819
2.754
2.784
2.844
2.806
2.843
2.816

2
2.810
2.783
2.790
2.787
2.793
2.781
2.799
2.786
2.766
2.790

SampleNumber:
3
4
2.777 2.799
2.799 2.820
2.785 2.795
2.809 2.862
2.820 2.846
2.733 2.801
2.781 2.802
2.836 2.815
2.795 2.778
2.823 2.802

5
2.803
2.812
2.866
2.823
2.823
2.823
2.820
2.836
2.835
2.780

6
2.788
2.807
2.826
2.816
2.807
2.844
2.813
2.808
2.783
2.804
Mean(x)

Mean
Maxvalue MinValue
2.795
2.81
2.777
2.799
2.82
2.774
2.810
2.866
2.785
2.819
2.862
2.787
2.807
2.846
2.754
2.794
2.844
2.733
2.810
2.844
2.781
2.815
2.836
2.786
2.800
2.843
2.766
2.803
2.823
2.78
2.805
Meanrange

Range
0.033
0.046
0.081
0.075
0.092
0.111
0.063
0.05
0.077
0.043
0.0671

LCL
2.773
2.773
2.773
2.773
2.773
2.773
2.773
2.773
2.773
2.773

XBar
CL
2.805
2.805
2.805
2.805
2.805
2.805
2.805
2.805
2.805
2.805

UCL
2.837
2.837
2.837
2.837
2.837
2.837
2.837
2.837
2.837
2.837

LCL
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000

RBar
CL
0.067
0.067
0.067
0.067
0.067
0.067
0.067
0.067
0.067
0.067

UCL
0.134
0.134
0.134
0.134
0.134
0.134
0.134
0.134
0.134
0.134

2
2.158
2.256
2.166
2.171
2.032
2.108
2.302
2.189
2.128
1.990

SampleNumber:
3
4
2.049 1.959
2.099 2.269
1.955 2.125
2.068 2.143
2.032 1.955
2.105 2.037
2.019 2.154
1.970 2.067
1.976 2.228
1.863 2.183

5
2.107
2.193
1.988
1.979
2.018
1.957
2.104
2.088
2.036
2.020

6
1.875
2.193
2.009
2.278
2.007
1.881
1.830
1.903
1.949
1.889
Mean(x)

Mean
Maxvalue MinValue
2.028
2.158
1.875
2.141
2.269
1.836
2.041
2.166
1.955
2.136
2.278
1.979
2.035
2.167
1.955
2.017
2.108
1.881
2.058
2.302
1.83
2.066
2.189
1.903
2.047
2.228
1.949
2.034
2.26
1.863
2.060
Meanrange

Range
0.283
0.433
0.211
0.299
0.212
0.227
0.472
0.286
0.279
0.397
0.3099

LCL
1.912
1.912
1.912
1.912
1.912
1.912
1.912
1.912
1.912
1.912

XBar
CL
2.060
2.060
2.060
2.060
2.060
2.060
2.060
2.060
2.060
2.060

UCL
2.209
2.209
2.209
2.209
2.209
2.209
2.209
2.209
2.209
2.209

LCL
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000

RBar
CL
0.310
0.310
0.310
0.310
0.310
0.310
0.310
0.310
0.310
0.310

UCL
0.620
0.620
0.620
0.620
0.620
0.620
0.620
0.620
0.620
0.620

FingerHeight(mm)
Day
20July
21July
22July
23July
24July
27July
28July
29July
30July
31July

1
2.021
1.836
2.004
2.177
2.167
2.016
1.939
2.179
1.962
2.260

Exhibit3

RAKESHANDSK:IATTACHEDTHENEWTABLESINANOTHERLANDSCAPEWORDDOCUMENT.
PLEASEDONOTINCLUDETHESETABLESBELOW.

Pod Weight
(grams)

20 July
21 July
22 July
23 July
24 July
27 July
28 July
29 July
30 July
31 July
Day

2.792
2.774
2.797
2.819
2.754
2.784
2.844
2.806
2.843
2.816

2.810
2.783
2.790
2.787
2.793
2.781
2.799
2.786
2.766
2.790

Sample Number:
4
5
6

2.777
2.799
2.785
2.809
2.820
2.733
2.781
2.836
2.795
2.823

2.799
2.820
2.795
2.862
2.846
2.801
2.802
2.815
2.778
2.802

2.803
2.812
2.866
2.823
2.823
2.823
2.820
2.836
2.835
2.780

X bar Chart Control Limits

2.788
2.807
2.826
2.816
2.807
2.844
2.813
2.808
2.783
2.804
Avg X
Bar

Mean
Max Value Min Value Range
LCL
CL
2.795
2.81
2.777
0.033
2.773
2.799
2.82
2.774
0.046
2.773
2.810
2.866
2.785
0.081
2.773
2.819
2.862
2.787
0.075
2.773
2.807
2.846
2.754
0.092
2.773
2.794
2.844
2.733
0.111
2.773
2.810
2.844
2.781
0.063
2.773
2.815
2.836
2.786
0.05
2.773
2.800
2.843
2.766
0.077
2.773
2.803
2.823
2.78
0.043
2.773
2.805

R Bar

2.805
2.805
2.805
2.805
2.805
2.805
2.805
2.805
2.805
2.805

R Chart Control Limit

UCL
LCL
CL
UCL
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134
2.837
0.000
0.067
0.134

0.0671

Finger Height
(mm)
Day
20 July
21 July
22 July
23 July
24 July
27 July
28 July
29 July
30 July
31 July

1
2.021
1.836
2.004
2.177
2.167
2.016
1.939
2.179
1.962
2.260

2
2.158
2.256
2.166
2.171
2.032
2.108
2.302
2.189
2.128
1.990

3
2.049
2.099
1.955
2.068
2.032
2.105
2.019
1.970
1.976
1.863

Sample Number:
X bar Chart
4
5
6
Mean
Max value Min Value Range
LCL
CL
1.959 2.107 1.875
2.028
2.158
1.875
0.283
1.912
2.269 2.193 2.193
2.141
2.269
1.836
0.433
1.912
2.125 1.988 2.009
2.041
2.166
1.955
0.211
1.912
2.143 1.979 2.278
2.136
2.278
1.979
0.299
1.912
1.955 2.018 2.007
2.035
2.167
1.955
0.212
1.912
2.037 1.957 1.881
2.017
2.108
1.881
0.227
1.912
2.154 2.104 1.830
2.058
2.302
1.83
0.472
1.912
2.067 2.088 1.903
2.066
2.189
1.903
0.286
1.912
2.228 2.036 1.949
2.047
2.228
1.949
0.279
1.912
2.183 2.020 1.889
2.034
2.26
1.863
0.397
1.912
Avg X
Bar
2.060
R Bar
0.3099

Control Limits
R Chart Control Limit
UCL
LCL
CL
UCL
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620
2.060
2.209
0.000
0.310
0.620

Exhibit4

Exhibit5
PodWeight(grams)
Day
3 August

4 August

5 August

6 August

7 August

10 August

11 August

12 August

13 August

14 August

17 August

18 August

19 August

20 August

21 August

X bar Chart
Shift
1
2
3
4
5
6 Mean
Max
Min
Range
LCL
CL
A 2.800 2.799 2.760 2.802 2.805 2.803
2.795
2.805
2.760
0.045
2.773
B 2.750 2.820 2.850 2.740 2.850 2.790
2.800
2.850
2.740
0.110
2.773
C 2.768 2.807 2.807 2.804 2.804 2.803
2.799
2.807
2.768
0.039
2.773
A 2.841 2.802 2.802 2.806 2.807 2.807
2.811
2.841
2.802
0.039
2.773
B 2.801 2.770 2.833 2.770 2.840 2.741
2.793
2.840
2.741
0.099
2.773
C 2.778 2.807 2.804 2.804 2.803 2.804
2.800
2.807
2.778
0.029
2.773
A 2.760 2.804 2.804 2.806 2.805 2.806
2.798
2.806
2.760
0.046
2.773
B 2.829 2.804 2.805 2.806 2.807 2.807
2.810
2.829
2.804
0.025
2.773
C 2.741 2.850 2.744 2.766 2.767 2.808
2.779
2.850
2.741
0.109
2.773

2.805

2.837

0.000

0.067

0.134

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.805

2.837

0.000

0.067

0.134

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.805

2.837

0.000

0.067

0.134

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

A
B

2.814 2.804 2.803 2.805 2.807 2.804

2.787 2.802 2.805 2.804 2.805 2.804

2.806

2.814

2.803

0.011

2.773

2.805
2.805

2.801

2.805

2.787

0.018

2.773

2.805

2.837

0.000

0.067

0.134

2.766 2.805 2.804 2.802 2.804 2.806

A
B

2.774 2.801 2.805 2.805 2.805 2.804

2.770 2.801 2.833 2.770 2.840 2.741

2.798
2.799

2.806
2.805

2.766
2.774

0.040
0.031

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.793

2.840

2.741

0.099

2.773

2.805

2.837

0.000

0.067

0.134

2.832 2.836 2.794 2.843 2.813 2.743

A
B

2.829 2.846 2.760 2.854 2.817 2.805

2.850 2.804 2.805 2.806 2.807 2.807

2.810
2.819

2.843
2.854

2.743
2.760

0.100
0.094

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.813

2.850

2.804

0.046

2.773

2.805

2.837

0.000

0.067

0.134

2.803 2.803 2.773 2.837 2.808 2.808

A
B

2.815 2.804 2.803 2.804 2.803 2.802

2.782 2.806 2.806 2.804 2.803 2.802

2.805
2.805

2.837
2.815

2.773
2.802

0.064
0.013

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.801

2.806

2.782

0.024

2.773

2.805

2.837

0.000

0.067

0.134

2.779 2.807 2.808 2.803 2.803 2.803

A
B

2.815 2.815 2.803 2.864 2.834 2.803

2.846 2.854 2.760 2.829 2.817 2.805

2.801
2.822

2.808
2.864

2.779
2.803

0.029
0.061

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.819

2.854

2.760

0.094

2.773

2.805

2.837

0.000

0.067

0.134

2.767 2.804 2.834 2.803 2.803 2.803

A
B

2.850 2.804 2.804 2.804 2.804 2.804

2.810 2.820 2.814 2.794 2.798 2.787

2.802
2.812

2.834
2.850

2.767
2.804

0.067
0.046

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.804

2.820

2.787

0.033

2.773

2.805

2.837

0.000

0.067

0.134

2.850 2.820 2.750 2.740 2.850 2.790

A
B

2.750 2.765 2.850 2.760 2.790 2.840

2.830 2.770 2.848 2.760 2.750 2.830

2.800
2.793

2.850
2.850

2.740
2.750

0.110
0.100

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.798

2.848

2.750

0.098

2.773

2.805

2.837

0.000

0.067

0.134

2.740 2.770 2.833 2.770 2.840 2.800

A
B

2.753 2.807 2.805 2.804 2.802 2.804

2.851 2.751 2.752 2.773 2.849 2.806

2.792
2.796

2.840
2.807

2.740
2.753

0.100
0.054

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.797

2.851

2.751

0.100

2.773

2.805

2.837

0.000

0.067

0.134

2.845 2.804 2.803 2.806 2.805 2.806

A
B

2.844 2.777 2.754 2.791 2.833 2.811

2.806 2.839 2.805 2.804 2.850 2.740

2.812
2.802

2.845
2.844

2.803
2.754

0.042
0.090

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.807

2.850

2.740

0.110

2.773

2.805

2.837

0.000

0.067

0.134

2.849 2.801 2.804 2.762 2.814 2.791

A
B

2.820 2.793 2.812 2.833 2.853 2.812

2.790 2.780 2.764 2.843 2.843 2.818

2.804
2.821

2.849
2.853

2.762
2.793

0.087
0.060

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.806

2.843

2.764

0.079

2.773

2.805

2.837

0.000

0.067

0.134

2.850 2.806 2.805 2.814 2.807 2.807

A
B

2.767 2.831 2.808 2.793 2.836 2.811

2.833 2.825 2.793 2.813 2.823 2.766

2.815
2.808

2.850
2.836

2.805
2.767

0.045
0.069

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.809

2.833

2.766

0.067

2.773

2.805

2.837

0.000

0.067

0.134

2.824 2.799 2.790 2.764 2.817 2.805

A
B

2.778 2.775 2.799 2.805 2.833 2.772

2.801 2.832 2.758 2.759 2.773 2.814

2.800
2.794

2.824
2.833

2.764
2.772

0.060
0.061

2.773
2.773

2.805
2.805

2.837
2.837

0.000
0.000

0.067
0.067

0.134
0.134

2.790

2.832

2.758

0.074

2.773

2.805

2.837

0.000

0.067

0.134

2.770 2.787 2.744 2.766 2.807 2.803

2.780

2.807

2.744

0.063

2.773

2.805

2.837

0.000

0.067

0.134

Control Limits
R Chart Control Limit
UCL
LCL
CL
UCL
2.805
2.837
0.000
0.067
0.134

FingerHeight(mm)
Day
3 August

4 August

5 August

6 August

7 August

10 August

11 August

12 August

13 August

14 August

17 August

18 August

19 August

20 August

21 August

Shift
A
B

1
1.90
2.15

2
1.95
2.17

3
1.94
2.11

4
2.00
2.13

5
2.05
2.02

1.73

1.90

2.07

1.89

1.76

A
B

2.30
2.28

2.41
2.16

2.54
2.19

2.37
2.08

2.32
2.25

1.92

2.24

2.11

1.89

1.88

A
B

2.39
2.11

2.28
2.21

2.10
2.24

2.36
2.21

2.54
2.17

1.89

1.90

1.73

2.07

1.89

X bar Chart
6 Mean
Max
Min
Range
LCL
CL
2.16
2.000
2.160
1.900
0.260
1.912
2.03
2.102
2.170
2.020
0.150
1.912
1.88
1.872
2.070
1.730
0.340
1.912
2.16
2.350
2.540
2.160
0.380
1.912
2.24
2.200
2.280
2.080
0.200
1.912
2.17
2.035
2.240
1.880
0.360
1.912
2.25
2.320
2.540
2.100
0.440
1.912
2.24
2.197
2.240
2.110
0.130
1.912
1.76
1.873
2.070
1.730
0.340
1.912

A
B

2.51
2.22

2.25
2.19

2.08
2.22

2.35
2.24

2.29
2.01

2.32
2.23

2.300

2.510

2.080

0.430

2.185

2.240

2.010

1.89

1.90

1.78

2.07

1.89

1.76

A
B

1.95
2.08

2.07
2.03

2.25
2.27

1.95
2.23

2.11
2.24

2.16
2.13

1.882
2.082

2.070
2.250

1.760
1.950

2.163

2.270

2.31

1.90

1.86

1.91

1.89

1.87

A
B

2.23
2.23

2.25
2.21

2.21
2.05

1.89
2.19

2.15
2.07

2.11
2.16

1.957
2.140

2.310
2.250

2.152

1.73

2.00

1.79

1.75

1.84

1.74

A
B

2.21
2.17

2.11
2.19

2.21
2.15

2.44
2.04

2.17
2.07

2.30
2.22

1.808
2.240

2.01

1.90

1.90

1.81

2.06

1.89

A
B

2.08
1.93

2.19
2.09

2.28
1.90

2.29
1.95

2.21
2.04

2.45
2.09

1.84

2.12

1.90

1.89

2.01

1.75

A
B

2.23
2.19

2.01
2.22

2.25
2.18

2.11
2.15

2.39
2.23

2.15
2.04

1.96

2.05

2.16

1.87

2.13

1.90

A
B

2.27
1.92

2.00
1.78

2.06
1.76

1.97
1.77

2.13
1.78

2.05
1.87

1.78

1.65

2.04

1.63

1.75

1.83

A
B

2.31
2.02

2.35
1.97

2.25
1.81

1.99
1.73

2.27
1.77

2.11
1.82

1.76

1.91

2.01

1.85

1.78

1.64

A
B

2.06
1.76

2.14
1.83

1.91
1.79

2.06
1.79

2.08
1.77

2.09
1.94

2.25

1.88

2.11

2.18

2.02

1.86

A
B

2.28
2.31

2.15
2.27

2.17
2.16

2.18
2.10

2.44
2.24

2.00
2.28

1.87

1.89

2.03

1.69

1.75

2.04

A
B

2.16
2.06

2.38
2.08

2.20
2.14

2.25
2.24

1.98
2.26

2.23
2.18

1.80

1.71

1.65

1.68

1.96

2.05

A
B
C

1.75
1.90
1.80

2.00
1.90
2.01

2.04
1.81
1.73

2.00
1.86
1.89

2.15
1.98
2.01

2.06
1.81
1.91

Control Limits
R Chart Control Limit
UCL
LCL
CL
UCL
2.060
2.209
0.000
0.310
0.620
2.060

2.209

0.000

0.310

0.620

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.060

2.209

0.000

0.310

0.620

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.060

2.209

0.000

0.310

0.620

1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

0.230

1.912

2.060

2.209

0.000

0.310

0.620

0.310
0.300

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.030

0.240

1.912

2.060

2.209

0.000

0.310

0.620

1.860
1.890

0.450
0.360

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.230

2.050

0.180

1.912

2.060

2.209

0.000

0.310

0.620

2.000
2.440

1.730
2.110

0.270
0.330

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.140

2.220

2.040

0.180

1.912

2.060

2.209

0.000

0.310

0.620

1.928
2.250

2.060
2.450

1.810
2.080

0.250
0.370

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.000

2.090

1.900

0.190

1.912

2.060

2.209

0.000

0.310

0.620

1.918
2.190

2.120
2.390

1.750
2.010

0.370
0.380

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.168

2.230

2.040

0.190

1.912

2.060

2.209

0.000

0.310

0.620

2.012
2.080

2.160
2.270

1.870
1.970

0.290
0.300

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

1.813

1.920

1.760

0.160

1.912

2.060

2.209

0.000

0.310

0.620

1.780
2.213

2.040
2.350

1.630
1.990

0.410
0.360

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

1.853

2.020

1.730

0.290

1.912

2.060

2.209

0.000

0.310

0.620

1.825
2.057

2.010
2.140

1.640
1.910

0.370
0.230

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

1.813

1.940

1.760

0.180

1.912

2.060

2.209

0.000

0.310

0.620

2.050
2.203

2.250
2.440

1.860
2.000

0.390
0.440

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.227

2.310

2.100

0.210

1.912

2.060

2.209

0.000

0.310

0.620

1.878
2.200

2.040
2.380

1.690
1.980

0.350
0.400

1.912
1.912

2.060
2.060

2.209
2.209

0.000
0.000

0.310
0.310

0.620
0.620

2.160

2.260

2.060

0.200

1.912

2.060

2.209

0.000

0.310

0.620

1.808
2.000
1.877
1.892

2.050
2.150
1.980
2.010

1.650
1.750
1.810
1.730

0.400
0.400
0.170
0.280

1.912
1.912
1.912
1.912

2.060
2.060
2.060
2.060

2.209
2.209
2.209
2.209

0.000
0.000
0.000
0.000

0.310
0.310
0.310
0.310

0.620
0.620
0.620
0.620

Exhibit6
PodWeight(grams)foreachshift
ShiftA
Day
3 August
4 August
5 August
6 August
7 August
10 August
11 August
12 August
13 August
14 August
17 August
18 August
19 August
20 August
21 August

Shift
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A

1
2.800
2.841
2.760
2.814
2.774
2.829
2.815
2.815
2.850
2.750
2.753
2.844
2.820
2.767
2.778

2
2.799
2.802
2.804
2.804
2.801
2.846
2.804
2.815
2.804
2.765
2.807
2.777
2.793
2.831
2.775

3
2.760
2.802
2.804
2.803
2.805
2.760
2.803
2.803
2.804
2.850
2.805
2.754
2.812
2.808
2.799

4
2.802
2.806
2.806
2.805
2.805
2.854
2.804
2.864
2.804
2.760
2.804
2.791
2.833
2.793
2.805

5
2.805
2.807
2.805
2.807
2.805
2.817
2.803
2.834
2.804
2.790
2.802
2.833
2.853
2.836
2.833

6 Mean
Max
Min
Range
LCL
CL
UCL
LCL
CL
UCL
2.803
2.795
2.805
2.760
0.045
2.773
2.805
2.837
0.000
0.067
0.134
2.807
2.811
2.841
2.802
0.039
2.773
2.805
2.837
0.000
0.067
0.134
2.806
2.798
2.806
2.760
0.046
2.773
2.805
2.837
0.000
0.067
0.134
2.804
2.806
2.814
2.803
0.011
2.773
2.805
2.837
0.000
0.067
0.134
2.804
2.799
2.805
2.774
0.031
2.773
2.805
2.837
0.000
0.067
0.134
2.805
2.819
2.854
2.760
0.094
2.773
2.805
2.837
0.000
0.067
0.134
2.802
2.805
2.815
2.802
0.013
2.773
2.805
2.837
0.000
0.067
0.134
2.803
2.822
2.864
2.803
0.061
2.773
2.805
2.837
0.000
0.067
0.134
2.804
2.812
2.850
2.804
0.046
2.773
2.805
2.837
0.000
0.067
0.134
2.840
2.793
2.850
2.750
0.100
2.773
2.805
2.837
0.000
0.067
0.134
2.804
2.796
2.807
2.753
0.054
2.773
2.805
2.837
0.000
0.067
0.134
2.811
2.802
2.844
2.754
0.090
2.773
2.805
2.837
0.000
0.067
0.134
2.812
2.821
2.853
2.793
0.060
2.773
2.805
2.837
0.000
0.067
0.134
2.811
2.808
2.836
2.767
0.069
2.773
2.805
2.837
0.000
0.067
0.134
2.772
2.794
2.833
2.772
0.061
2.773
2.805
2.837
0.000
0.067
0.134

Shift
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B

1
2.750
2.801
2.829
2.787
2.770
2.850
2.782
2.846
2.810
2.830
2.851
2.806
2.790
2.833
2.801

2
2.820
2.770
2.804
2.802
2.801
2.804
2.806
2.854
2.820
2.770
2.751
2.839
2.780
2.825
2.832

3
2.850
2.833
2.805
2.805
2.833
2.805
2.806
2.760
2.814
2.848
2.752
2.805
2.764
2.793
2.758

4
2.740
2.770
2.806
2.804
2.770
2.806
2.804
2.829
2.794
2.760
2.773
2.804
2.843
2.813
2.759

5
2.850
2.840
2.807
2.805
2.840
2.807
2.803
2.817
2.798
2.750
2.849
2.850
2.843
2.823
2.773

6 Mean
Max
Min
Range
LCL
CL
UCL
LCL
CL
UCL
2.790
2.800
2.850
2.740
0.110
2.773
2.805
2.837
0.000
0.067
0.134
2.741
2.793
2.840
2.741
0.099
2.773
2.805
2.837
0.000
0.067
0.134
2.807
2.810
2.829
2.804
0.025
2.773
2.805
2.837
0.000
0.067
0.134
2.804
2.801
2.805
2.787
0.018
2.773
2.805
2.837
0.000
0.067
0.134
2.741
2.793
2.840
2.741
0.099
2.773
2.805
2.837
0.000
0.067
0.134
2.807
2.813
2.850
2.804
0.046
2.773
2.805
2.837
0.000
0.067
0.134
2.802
2.801
2.806
2.782
0.024
2.773
2.805
2.837
0.000
0.067
0.134
2.805
2.819
2.854
2.760
0.094
2.773
2.805
2.837
0.000
0.067
0.134
2.787
2.804
2.820
2.787
0.033
2.773
2.805
2.837
0.000
0.067
0.134
2.830
2.798
2.848
2.750
0.098
2.773
2.805
2.837
0.000
0.067
0.134
2.806
2.797
2.851
2.751
0.100
2.773
2.805
2.837
0.000
0.067
0.134
2.740
2.807
2.850
2.740
0.110
2.773
2.805
2.837
0.000
0.067
0.134
2.818
2.806
2.843
2.764
0.079
2.773
2.805
2.837
0.000
0.067
0.134
2.766
2.809
2.833
2.766
0.067
2.773
2.805
2.837
0.000
0.067
0.134
2.814
2.790
2.832
2.758
0.074
2.773
2.805
2.837
0.000
0.067
0.134

Shift
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C

1
2.768
2.778
2.741
2.766
2.832
2.803
2.779
2.767
2.850
2.740
2.845
2.849
2.850
2.824
2.770

2
2.807
2.807
2.850
2.805
2.836
2.803
2.807
2.804
2.820
2.770
2.804
2.801
2.806
2.799
2.787

3
2.807
2.804
2.744
2.804
2.794
2.773
2.808
2.834
2.750
2.833
2.803
2.804
2.805
2.790
2.744

4
2.804
2.804
2.766
2.802
2.843
2.837
2.803
2.803
2.740
2.770
2.806
2.762
2.814
2.764
2.766

5
2.804
2.803
2.767
2.804
2.813
2.808
2.803
2.803
2.850
2.840
2.805
2.814
2.807
2.817
2.807

6 Mean
Max
Min
Range
LCL
CL
UCL
LCL
CL
UCL
2.803
2.799
2.807
2.768
0.039
2.773
2.805
2.837
0.000
0.067
0.134
2.804
2.800
2.807
2.778
0.029
2.773
2.805
2.837
0.000
0.067
0.134
2.808
2.779
2.850
2.741
0.109
2.773
2.805
2.837
0.000
0.067
0.134
2.806
2.798
2.806
2.766
0.040
2.773
2.805
2.837
0.000
0.067
0.134
2.743
2.810
2.843
2.743
0.100
2.773
2.805
2.837
0.000
0.067
0.134
2.808
2.805
2.837
2.773
0.064
2.773
2.805
2.837
0.000
0.067
0.134
2.803
2.801
2.808
2.779
0.029
2.773
2.805
2.837
0.000
0.067
0.134
2.803
2.802
2.834
2.767
0.067
2.773
2.805
2.837
0.000
0.067
0.134
2.790
2.800
2.850
2.740
0.110
2.773
2.805
2.837
0.000
0.067
0.134
2.800
2.792
2.840
2.740
0.100
2.773
2.805
2.837
0.000
0.067
0.134
2.806
2.812
2.845
2.803
0.042
2.773
2.805
2.837
0.000
0.067
0.134
2.791
2.804
2.849
2.762
0.087
2.773
2.805
2.837
0.000
0.067
0.134
2.807
2.815
2.850
2.805
0.045
2.773
2.805
2.837
0.000
0.067
0.134
2.805
2.800
2.824
2.764
0.060
2.773
2.805
2.837
0.000
0.067
0.134
2.803
2.780
2.807
2.744
0.063
2.773
2.805
2.837
0.000
0.067
0.134

ShiftB
Day
3 August
4 August
5 August
6 August
7 August
10 August
11 August
12 August
13 August
14 August
17 August
18 August
19 August
20 August
21 August

ShiftC
Day
3 August
4 August
5 August
6 August
7 August
10 August
11 August
12 August
13 August
14 August
17 August
18 August
19 August
20 August
21 August

FingerHeight(mm)foreachshift
ShiftA
Day
3 August
4 August
5 August
6 August
7 August
10 August
11 August

Shift
A
A
A
A
A
A
A

1
1.90
2.30
2.39
2.51
1.95
2.23
2.21

2
1.95
2.41
2.28
2.25
2.07
2.25
2.11

3
1.94
2.54
2.10
2.08
2.25
2.21
2.21

4
2.00
2.37
2.36
2.35
1.95
1.89
2.44

5
2.05
2.32
2.54
2.29
2.11
2.15
2.17

12 August
13 August
14 August
17 August

A
A
A
A

2.08
2.23
2.27
2.31

2.19
2.01
2.00
2.35

2.28
2.25
2.06
2.25

2.29
2.11
1.97
1.99

2.21
2.39
2.13
2.27

18 August
19 August
20 August
21 August

A
A
A
A

2.06
2.28
2.16
1.75

2.14
2.15
2.38
2.00

1.91
2.17
2.20
2.04

2.06
2.18
2.25
2.00

2.08
2.44
1.98
2.15

6
mean
Max
Min
Range
LCL
CL
UCL
LCL
CL
UCL
2.16
2.00
2.16
1.90
0.26
1.912
2.060
2.209
0.000
0.310
0.620
2.16
2.35
2.54
2.16
0.38
1.912
2.060
2.209
0.000
0.310
0.620
2.25
2.32
2.54
2.10
0.44
1.912
2.060
2.209
0.000
0.310
0.620
2.32
2.30
2.51
2.08
0.43
1.912
2.060
2.209
0.000
0.310
0.620
2.16
2.08
2.25
1.95
0.30
1.912
2.060
2.209
0.000
0.310
0.620
2.11
2.14
2.25
1.89
0.36
1.912
2.060
2.209
0.000
0.310
0.620
2.30
2.24
2.44
2.11
0.33
1.912
2.060
2.209
0.000
0.310
0.620
2.45
2.25
2.45
2.08
0.37
1.912
2.060
2.209
0.000
0.310
0.620
2.15
2.19
2.39
2.01
0.38
1.912
2.060
2.209
0.000
0.310
0.620
2.05
2.08
2.27
1.97
0.30
1.912
2.060
2.209
0.000
0.310
0.620
2.11
2.21
2.35
1.99
0.36
1.912
2.060
2.209
0.000
0.310
0.620
2.09
2.06
2.14
1.91
0.23
1.912
2.060
2.209
0.000
0.310
0.620
2.00
2.20
2.44
2.00
0.44
1.912
2.060
2.209
0.000
0.310
0.620
2.23
2.20
2.38
1.98
0.40
1.912
2.060
2.209
0.000
0.310
0.620
2.06
2.00
2.15
1.75
0.40
1.912
2.060
2.209
0.000
0.310
0.620

Shift
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B

1
2.15
2.28
2.11
2.22
2.08
2.23
2.17
1.93
2.19
1.92
2.02
1.76
2.31
2.06
1.90

2
2.17
2.16
2.21
2.19
2.03
2.21
2.19
2.09
2.22
1.78
1.97
1.83
2.27
2.08
1.90

3
2.11
2.19
2.24
2.22
2.27
2.05
2.15
1.90
2.18
1.76
1.81
1.79
2.16
2.14
1.81

4
2.13
2.08
2.21
2.24
2.23
2.19
2.04
1.95
2.15
1.77
1.73
1.79
2.10
2.24
1.86

5
2.02
2.25
2.17
2.01
2.24
2.07
2.07
2.04
2.23
1.78
1.77
1.77
2.24
2.26
1.98

6
mean
Max
Min
Range
LCL
CL
UCL
LCL
CL
UCL
2.03
2.10
2.17
2.02
0.15
1.912
2.060
2.209
0.000
0.310
0.620
2.24
2.20
2.28
2.08
0.20
1.912
2.060
2.209
0.000
0.310
0.620
2.24
2.20
2.24
2.11
0.13
1.912
2.060
2.209
0.000
0.310
0.620
2.23
2.19
2.24
2.01
0.23
1.912
2.060
2.209
0.000
0.310
0.620
2.13
2.16
2.27
2.03
0.24
1.912
2.060
2.209
0.000
0.310
0.620
2.16
2.15
2.23
2.05
0.18
1.912
2.060
2.209
0.000
0.310
0.620
2.22
2.14
2.22
2.04
0.18
1.912
2.060
2.209
0.000
0.310
0.620
2.09
2.00
2.09
1.90
0.19
1.912
2.060
2.209
0.000
0.310
0.620
2.04
2.17
2.23
2.04
0.19
1.912
2.060
2.209
0.000
0.310
0.620
1.87
1.81
1.92
1.76
0.16
1.912
2.060
2.209
0.000
0.310
0.620
1.82
1.85
2.02
1.73
0.29
1.912
2.060
2.209
0.000
0.310
0.620
1.94
1.81
1.94
1.76
0.18
1.912
2.060
2.209
0.000
0.310
0.620
2.28
2.23
2.31
2.10
0.21
1.912
2.060
2.209
0.000
0.310
0.620
2.18
2.16
2.26
2.06
0.20
1.912
2.060
2.209
0.000
0.310
0.620
1.81
1.88
1.98
1.81
0.17
1.912
2.060
2.209
0.000
0.310
0.620

Shift
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C

1
1.73
1.92
1.89
1.89
2.31
1.73
2.01
1.84
1.96
1.78
1.76
2.25
1.87
1.80
1.80

2
1.90
2.24
1.90
1.90
1.90
2.00
1.90
2.12
2.05
1.65
1.91
1.88
1.89
1.71
2.01

3
2.07
2.11
1.73
1.78
1.86
1.79
1.90
1.90
2.16
2.04
2.01
2.11
2.03
1.65
1.73

4
1.89
1.89
2.07
2.07
1.91
1.75
1.81
1.89
1.87
1.63
1.85
2.18
1.69
1.68
1.89

5
1.76
1.88
1.89
1.89
1.89
1.84
2.06
2.01
2.13
1.75
1.78
2.02
1.75
1.96
2.01

6
mean
Max
Min
Range
LCL
CL
UCL
LCL
CL
UCL
1.88
1.87
2.07
1.73
0.34
1.912
2.060
2.209
0.000
0.310
0.620
2.17
2.04
2.24
1.88
0.36
1.912
2.060
2.209
0.000
0.310
0.620
1.76
1.87
2.07
1.73
0.34
1.912
2.060
2.209
0.000
0.310
0.620
1.76
1.88
2.07
1.76
0.31
1.912
2.060
2.209
0.000
0.310
0.620
1.87
1.96
2.31
1.86
0.45
1.912
2.060
2.209
0.000
0.310
0.620
1.74
1.81
2.00
1.73
0.27
1.912
2.060
2.209
0.000
0.310
0.620
1.89
1.93
2.06
1.81
0.25
1.912
2.060
2.209
0.000
0.310
0.620
1.75
1.92
2.12
1.75
0.37
1.912
2.060
2.209
0.000
0.310
0.620
1.90
2.01
2.16
1.87
0.29
1.912
2.060
2.209
0.000
0.310
0.620
1.83
1.78
2.04
1.63
0.41
1.912
2.060
2.209
0.000
0.310
0.620
1.64
1.83
2.01
1.64
0.37
1.912
2.060
2.209
0.000
0.310
0.620
1.86
2.05
2.25
1.86
0.39
1.912
2.060
2.209
0.000
0.310
0.620
2.04
1.88
2.04
1.69
0.35
1.912
2.060
2.209
0.000
0.310
0.620
2.05
1.81
2.05
1.65
0.40
1.912
2.060
2.209
0.000
0.310
0.620
1.91
1.89
2.01
1.73
0.28
1.912
2.060
2.209
0.000
0.310
0.620

ShiftB
Day
3 August
4 August
5 August
6 August
7 August
10 August
11 August
12 August
13 August
14 August
17 August
18 August
19 August
20 August
21 August

ShiftC
Day
3 August
4 August
5 August
6 August
7 August
10 August
11 August
12 August
13 August
14 August
17 August
18 August
19 August
20 August
21 August