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Quality Case Study – Finding the Problem
Assignment Instructions
Select a company/activity from list:
GM ignition switch recall
Boeing 737 Max pull back
Federal Food & Drug Administration and control of generic drugs
2020 Iowa Caucus
College Admissions Scandal
Introduction: What is the company or activity?  What do they produce?
What was the quality issue and what were the resulting costs / losses?
Develop a fishbone chart highlighting the key causes of the problem.
Perform a five why analysis to get to root cause(s).
Select one of the following quality processes and discuss how this could have prevented the problem or be used to control the problem
PDC
TQ
Six Sigma / DMAI
Conclusion
Follow APA format for structure, references, and citations.
Fishbone Diagram and Five Why Instructions
Using the categories of Measurement, Materials/Supplies, Manpower, Machine/IT, Mother Nature, Methods. Follow the directions provided in your Lean Pocket Guide (pp. 63-65). Then once you have completed the Fishbone chart, develop a Five Why Worksheet for your problem using the instructions in the Lean Pocket Guide (pp.66-68) **I’ve screenshot below.
Utilize the following 5 Whys Analysis worksheets (Links to an external site.)
Informational videos are here:
How to create a Fishbone Diagram(Fishbone Diagram tutorial)Links to an external site.  Fishbone diagram tutorial
How to do a 5 Why Analysis Video LinkLinks to an external site.
***You should be able to Ctrl click on the links provided above in the attached file.
Lean Pocket Guide (pp.66-68)
Pages are in the file attached.

 

Struggling with where to start this assignment? Follow this guide to tackle your assignment easily!

Step 1: Understanding the Assignment

In this assignment, you will be analyzing a quality issue that arose in a company or activity of your choice. Your goal is to identify the causes of the problem using a Fishbone Diagram and perform a Five Why analysis to uncover the root cause(s). You will also explore how a quality process could have prevented or controlled the problem.

Step 2: Select a Company or Activity

• Choose one of the following options for your case study:
  1. GM Ignition Switch Recall
  2. Boeing 737 Max Pullback
  3. Federal Food & Drug Administration and Control of Generic Drugs
  4. 2020 Iowa Caucus
  5. College Admissions Scandal
• Once selected, research the company/activity to understand what they produce and the quality issue they faced. This will be the foundation for the rest of your analysis.

Step 3: Introduction Section

• What is the company or activity?: Briefly introduce the company or activity. Include key details about what they do and the products or services they provide.
• What was the quality issue?: Identify and describe the specific quality issue that occurred. What went wrong, and how did it impact the company or its stakeholders?
• Costs and Losses: What were the resulting costs or losses from the quality issue? This could include financial costs, reputational damage, or legal consequences.

Step 4: Create the Fishbone Diagram

• Identify the Key Causes: Use the categories provided (Measurement, Materials/Supplies, Manpower, Machine/IT, Mother Nature, Methods) to help you organize the causes of the problem.
• Fishbone Diagram:
  • Draw the Fishbone diagram, listing the major causes of the problem along the bones and sub-causes along smaller branches.
  • Consider factors like human error, equipment failures, process flaws, or environmental influences.
• Tools: Use the provided links and videos on creating a Fishbone Diagram and Five Why Analysis to guide you through the process.

Step 5: Perform a Five Why Analysis

• Use the 5 Whys Worksheet: Start by identifying the main problem (e.g., product defect, system failure) and ask “Why?” five times, each time getting closer to the root cause.
• Fill out the Worksheet: Document each question and answer as you work through the analysis.
• Identify the Root Cause(s): After the 5 Whys, you should have a clearer understanding of what caused the problem at its core.

Step 6: Select a Quality Process

• Choose One Quality Process: From the following options, select one process to discuss and how it could have prevented or controlled the problem:
  1. PDC (Plan-Do-Check): Could this process have helped by identifying the problem early in the planning or execution stages?
  2. TQ (Total Quality): Would a total quality management approach have improved the overall process and avoided the issue?
  3. Six Sigma/DMAI: Could Six Sigma have been used to improve the process or reduce defects?
• Discuss the Chosen Process: Explain how the selected quality process could have been applied to prevent or address the quality issue. Provide a rationale for your choice, highlighting the benefits of using this process in the situation.

Step 7: Conclusion Section

• Summarize the Analysis: Recap the key findings from your Fishbone Diagram, Five Why analysis, and the quality process you chose to apply.
• Discuss the Impact of Preventing the Issue: Reflect on how implementing the chosen quality process could have mitigated the issue and the potential long-term benefits.

Step 8: Finalizing Your Paper

• APA Format: Make sure your paper follows the proper APA format for structure, references, and citations.
  • Use in-text citations for any sources you reference.
  • Include a references page with all the materials you used in your research.
• Review Your Work: Proofread your paper for clarity, structure, and grammatical correctness.

Step 9: Fishbone Diagram and 5 Why Worksheet Submission

• Submit the Fishbone Diagram: Attach the completed Fishbone Diagram to your paper.
• Submit the Five Why Worksheet: Include your filled-out Five Why Worksheet in the submission.

 

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