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Quality Improvements in Plasti-Brack Product Line

Quality Improvements in Plasti-Brack Product Lines

The concept of quality management has helped many manufacturing companies to reduce waste, produce better quality products and improve customer satisfaction. The introduction of quality department in EMC is therefore a good step that can help attain overall improvement in product quality and customer satisfaction. There are various processes involved in setting up quality management system and this calls for the formation of a committee to oversee the smooth implementation of the processes. The effective implementation of the process is aimed at eliminating the complaints from customers and occasional returns of products. 

Utilization of Six Sigma Program

The sigma program can be used to eliminate wastage and improve customer satisfaction. It embraces the concept of lean management and emphasizes production of goods based on customer specifications. Sigma methodologies can help in identification of the quality problems in the manufacture of plasti-brack products. It also collects measures and analyzes key aspects and is able to investigate and verify the cause and effect of the problem. This is then used to improve the production process using relevant techniques such as design experiments. Control measures are then designed to ensure that the recommended process is adhered to and any defects are corrected in time. These control systems include statistical process control, quality department among others tasked with monitoring the process of production to provide high quality products and customer satisfaction, (Coryea, Cordy & Coryea, 2006). 

7 Step Quality Improvement Plan

Step 1

The first Step in developing the quality improvement plan is to define the actual process. This provides the ground for improving the manufacturing process. This Step entails naming the process and stating its purpose as well as stating the starting and ending points of the quality management process. It is also necessary to state the inputs needed and expected outputs as well as the overall resources required in implementing quality improvement process in the organization. It is also important to identify the suppliers and customers likely to be affected by the process.

Step 2

This Step entails identification of the areas which needs to be improved. The main products and areas that need to be improved. Some of these areas and products in the EMC Company have already been identified by process operators. These include the assembly of section where 10.ft. tubs accumulate in Plastic-Brack assembly. Plating, finishing and sharp edges on Plasti-Brack products have received complaints and needs to be improved upon. 

Step 3

Identification of possible solutions for the problems is done at this phase. Identification of problems is usually followed with the process of finding their solutions. It is the Step of brainstorming and consulting specialists in the manufacturing plants. This is aimed at arriving at the best probable solution to the problem facing the quality system.  Getting feedback from the process operators will provide useful information for developing solutions to quality problems.


This involves coming up with a more detailed solution for every problem area. It includes the budget and personnel required for the improvements, projection of cost analysis and time frame for effecting the overall improvements. It is also necessary to find out how the plant will be affected by the process. 

Step 5

This is the actualization of developed plan. It involves everyone and this is time the to implement the plan to improve the process of production that will meet the required standard and enhance customer satisfaction. All workers in the manufacturing plant, from the top most level to the lowest level workers are incorporated.

Step 6

This is the evaluation phase. The results obtained are evaluated against the expected results. The new quality manager should be able to ascertain whether the process was successful, whether it fixed the problem and if it eliminated the wastes. Evaluate whether it worked within the budget and time frame and whether it met the desired effect.


At this point, the process is repeated severally from step one to six until it achieves the desired results within the EMC manufacturing plant. The success of the process results in elimination of the implementation committee and leaving the quality department to continue with the process of ensuring quality goods are produced, (Christopher and Thor, 2000).

Justification of The Plan

The plan is applicable to the improvement of quality plasti-Brack products in the EMC Company. This is because it takes into consideration the organizational characteristics of the EMC. It also specifies the purpose of the process which has been the main objective of hiring the quality manager. It is therefore a reflection of EMC values, aspirations and nature of the company. The increasing complaints from customers can be reduced drastically if the plan is effectively followed by the implementers.

The plan seems to be flexible and capitalizes on the already existing strengths within the organization. The company has got process operators who are able to produce quality products as directed by the quality team. This will help to eliminate customer complaints and increase profitability. It accommodates all members of the organization which makes them the opportunity to own the process. The plan seems to fit well into the structure of the company, starting with the formation of implementation committee and quality assurance department assisted with process operators as well as other supporting units that exists in different departments within the organization.


Quality improvement in manufacturing plant is necessary in the current competitive global market. The adoption of TQM emphasizes customer satisfaction through production of quality products that meets customer’s demands. Having a quality assurance department is essential in ensuring that quality products are produced and wastages are minimized. This requires the cooperation from member of the company. A good plan should therefore, be able to accommodate all members of the organization as well as other stakeholders.


 Coryea, L., Cordy, C, E. & Coryea, l. R. (2006). Champion's Practical Six Sigma Summary. New Orleans: Xlibris Corporation. 

Christopher, W. F. and Thor, C.G. (2000). World-Class Quality & Productivity. Financial World Publishing Canterbury, Kent: United Kingdom.

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