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Imagine that you have been hired as the new Quality Vice President for a manufacturing company that makes motorcycles. The company manufactures 12 million units in ten models, and the company has been successful in the past five years in exporting at least 50% of the products. Increasingly though, competition has been tough from other overseas manufacturers and the company is beginning to feel the pressure to innovate product offerings, improve quality, and cut waste from all processes.
Your primary job will be to enhance the quality of the organization and products, and create a company-wide program for continuous improvement. You can also propose a way to evaluate and streamline the product offering. You will be reporting to the CEO who thinks that by using Lean Six-Sigma principles, ISO 9000, theory of constraints, Malcolm Baldridge National Quality Award criteria (https://www.nist.gov/baldrige/how-baldrige-worksLinks to an external site.) and other world-class ideas the company can become a leader in its market class. The CEO would like you to create a report and a step-by-step action plan on how a quality and continuous improvement program should be implemented for the company.
The report needs to be professionally created with a table of contents, executive summary and a conclusion section. The body of the report needs to address the following overall questions. The page limit is 8-10 pages, 1.5 space with 12 font. The table of contents and references can be extra.
Give an overview to allow the CEO and top management team to understand what Lean Six-Sigma principles, ISO 9000, theory of constraints, Malcolm Baldridge National Quality Award criteria, and other world-class ideas are.
Compare and contrast each of these and recommend which should be enthusiastically embraced by the company and why. Mention instances of companies that have succeeded and failed using the tools that you recommend and how the company should plan to avoid failure.
Create a scenario of how you recommend the company create a continuous improvement program for organizational and product quality? What would be the action items needed to achieve this?
What specific tools (DMAIC, DOE, GR&R, etc.) do you recommend the company concentrate on and how should the company go about training employees.
How will the employees be empowered to get fully engaged in the program?
What metrics do you recommend the company use to evaluate the success of the continuous improvement program?
Note: This assignment is a good exercise for getting ready to appear for the comprehensive exam for the MSTM program also.