Six Sigma

When a senior product inspector at Plush Packet Inc. (PPI) inspected a shipment of Router the Raccoon plush toys she discovered that, on average, 15 of the 50 toys in every box had defective seams, and in many of the defective toys, the seams were already broken and the toy was losing its "stuffing." The defective toys had to be scrapped, because they would cause a hazard for young children.

The inspector was not sure if it was a mechanical problem (a sewing machine did not perform correctly), a human resource problem (the individual wasn't doing the task correctly, either on purpose or because he or she needed to be trained), or a quality problem (the thread was too weak). This high level of scrapped toys meant lost profits for PPI.

Write a 3- to 4-page Six Sigma proposal paper in which you explain how you would apply the Six Sigma approach to address, and resolve, the problem of too many defective toys. Describe each of the elements of the DMAIC approach, and apply them to this problem. Be sure to explain which elements of the organization, and its processes, you would examine and what data you would seek to gather. To ensure the successful implementation of the analysis and the changes it may require, identify any issues related to organizational culture that may arise.