UNIVERSITI UTARA MALAYSIA

FIRST SEMESTER, 2022/2023 SESSION

A221 BJMQ3013
QUALITY MANAGEMENT
GROUP G

INDIVIDUAL ASSIGNMENT
Quality Problem Solving

PREPARED FOR:

DR. SITI ZAKIAH BINTI ABU

BAKAR PREPARED BY:

NO NAME NUMBER
MATRIC
1. NOR ATIKAH BINTI MOHAMAD NOR 286919

SUBMISSION DATE:

31 December 2022
Consider the following scenario: Company XYZ is engaged in the manufacturing of
branded sports shoes. The market's rapid expansion has compelled this company to
maintain quality in order to compete with its rivals. However, because this product was
discovered to be flawed, this company's revenues declined in the final quarter of 2021. In
order to solve this issue, analysis and root-cause discovery are required. A thorough
investigation revealed that the inadequate quality of the raw materials used to manufacture
sports shoes is the cause of "many defect products."

The problem in the scenario above : " Defects Product "

The options for solving the problem in the scenario as follows ;

1. Cause and Effect Diagram or Fishbone

A fishbone diagram is a cause-and-effect discovery tool that helps find out the various
reasons for failure or damage in a process. It can also be said that fishbone analysis is a
method to help solve a problem at each layer to the potential root cause that contributes to
the effect. This diagram was introduced by a technical professor from Japan, named Kaoru
Ishikawa.

Therefore, to solve this problem, the Cause and Effect Diagram or Fishbone, which is part of
the Seven Quality Tools, is used as a source of the root cause of the problem by analyzing
the causes of the main problems that occur in XYZ company. In this research, the problem
that is the basis of Fishbone is the many defects that occur in the production process of the
branded sports shoes. Therefore, from the root of this problem, the causes of this problem
will be analyzed from branch to root until the root of the main problem is found.

Diagram 1 : Fishbone Defects Products

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According to the data processing that has been done, a number of reasons that may be the
primary cause of the issue of many defective goods are responsible for the lack of efficient
production. The causes of that facet will be examined through the Fishbone diagram. Four
components—manpower, machine, method, and material—make up the cause. Machine
damage and incorrect production machine setting are currently the secondary factors that
may have an impact on the primary cause of the machine bone. The production layout may
be the root of the secondary issue in the Method bone. Two factors, namely the poor quality
of the raw material and the raw material supplier, could be the root of secondary issues in the
Material bone. Next, the workforce's poor skill level and lack of job knowledge are potential
contributors to secondary issues in the Manpower bone. At this point, additional analysis is
performed, and if it is determined that there are no tertiary causes that could have an impact
on the secondary causes, the secondary causes are declared to be the primary causes of
each problem. It is anticipated that the outcome of the investigation into the secondary
sources of this issue is, for instance ;

1) The machine's age and lack of routine maintenance may be the secondary problem in the
machine bone, which leads to machine damage, while a lack of Standard Operating
Procedure (SOP) knowledge may be the primary reason of the production machine's setting
error bone.

2) The potential root of the tertiary issue with the bone The production layout's method bone
is a result of the less appealing and efficient layout design.

3) Potential root causes of tertiary bone issues The raw material supplier's bone is slow to
supply the raw material on time, which results in a low quality raw material that is expensive
or difficult to obtain.

4) Low workforce ability and a lack of comprehension of the job owing to inexperience or
lack of enthusiasm are two probable causes of secondary issues in the Manpower bone.

The significant elements of each factor on the fishbone results revealed that it is possible to
determine each factor's likelihood of actually having an impact on the quantity of defective
branded shoe products. According to the fishbone diagram shown above, the frequency of
defective goods is reportedly affected by the workforce, operating systems, and machine
employee in addition to low-quality components or raw materials.

In conclusion, from the analysis's findings, it can be inferred that fishbone diagrams can paint
a precise image of the root of an issue or effect. The identification of the precise cause
serves as the foundation for devising or preparing a programme to address the consequence
or problem.

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 2. Check Sheet

The first of seven fundamental simple quality management tools, known as a check sheet or
checklist or tally chart, is used to record and categorise the data that has been observed. A
check sheet is a list that includes or contains the variables that need to be looked at. A check
sheet is another list that includes components that might be present in the circumstance, the
observed individuals' actions, or their conduct.

An observation sheet check sheet used to inspect for defects in branded sports shoe in XYZ
company items seeks to offer data on product defects, including the time of observation, the
nature of the issue or defect, and the quantity of defects present. An example of a defective
data check sheet for branded sports shoes for the months of October to December 2021 is
shown in Table 1.

Table 1 : Check Sheet Branded Sports Shoes Defects

Months Output Goods Defects Defects Types

8 Incorrect shoes sizing

3 Abrassion marks
October 1 Excess Bluetooth,was or oil
0 Low-quality material

Total 46 34 12

11 Incorrect shoes sizing

4 Abrassion marks
November 2 Excess Bluetooth,was or oil
1 Low-quality material

Total 95 77 18

9 Incorrect shoes sizing

2 Abrassion marks
December 3 Excess Bluetooth,was or oil
1 Low-quality material

Total 61 46 15

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According to the Check Sheet above, it can be inferred that using a check mark to
indicate that a statement or a question has been explored is one way to collect data.
To prevent any errors during data collecting, this tool is designed as a straightforward
data recording sheet. The Check Sheet often comprises questions that are
constructed so that the recorder only needs to mark the available columns and enter
the appropriate data. Therefore, in order to decrease the amount of errors or defects
discovered during the production of branded sports shoes at XYZ company, the
Check Sheet is utilised to identify numerous problems. With this approach, it is
simpler to identify the kind of manufacturing defect that exists and to fix the
problematic product before it is put on the market. Based on the results of the above
research, it can be concluded that, the types of damage that occur in the production
process of branded sports shoes at XYZ company are four types, which are
dominated by incorrect shoes sizing, XYZ Company is recommended to overcome
defects caused by factors that is in accordance with the existing problem. Quality
control with the seven tools method is done so that the production of XYZ company's
products is more effective and efficient, so that it can satisfy customers with good
quality and increase profits for the company.

In conclusion, a good solution option to solve the problem that occurs is the Check
Sheet because it can collect data completely, accurately, and as easily as possible.
The data in the check sheet, both in the form of quantitative and qualitative data, can
be analyzed quickly (directly) or become data input for other quality equipment, for
example for Pareto chart data input compared to Fishbone because able to visually
limit the ability of the team or user in explaining the problem that uses the deep "level
why" method although able to provide a specific picture of the cause of an effect or
problem.

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References

Tague, N. R. (2005). The quality toolbox. (2th ed.). Milwaukee, Wisconsin: ASQ
Quality Press. Retrieved from http://asq.org/quality-press/display-
item/index.html?item=H1224

Ishikawa, K. (1982). Guide to quality control (Second Revised English Edition).

Tokyo, Japan: Asian Productivity Organization.

FISHBONE DIAGRAM / CAUSE EFFECT DIAGRAM. (2019). Retrieved from

https://bibinggo.wordpress.com/2010/08/18/fishbone-diagram-cause-effect-diagram/