Analysis

• DOUG FRIESEN implemented “five whys” to find the root of the

problem.
• Why this is happening?- Product proliferation, Reduce variability that
might be caused by changes in inputs for the new seats or in process
parameters.
• Implementing a control chart that distinguishes the source of
variability.
• Why KFS is allowing defective products to reach TMM?- They have a
poor-quality control system that can be addressed by sending a QC
team to train employees at KFS.
Contd..
Why is TMM being so slow to handle cars with seat problems?- KFS is consistently
sending the wrong seats to TMM.

Why are they sending the wrong seats?- Due to manual communication methods, TMM
in sending handwritten orders that might not be understood by KFS employees.

Implementing enterprise resource planning solution, to manage communication

designate a QC team that checks the seats immediately when they arrive to TMM.

Why is TPS failing?- They are not fixing the seats in the production line Extensive re-
education is needed to internalize the TPS system as a philosophy instead of using it
only as just a tool.