A manufacturer of small residential dehumidifiers has been receiving numerous customer complaints concerning quality problems and backorders. Apparently, the demand for dehumidifiers, which is seasonal, is difficult to accurately forecast, and when customers run low on inventories and reorder, the lead times are so long that the season may be over before replenishment stocks arrive. Quality is also a problem and many units have been returned from consumers for warranty repairs. A Pareto analysis has revealed that the two most frequently occurring problems are circuit board failures and compressor seizures. When these problems occur consumers are unhappy because their units are out of service for repairs during most of the season.
a. What would be the advantages to forming a kaizen blitz team to investigate these problems?
b. Who should be on the team?
c. If you were on the team, how would you suggest the team proceed, given that improvement recommendations are due in one week?
d. Do you think that there is any difference between the characteristics of a kaizen blitz team and any other team? Explain.