For stamping out prefabricated metal coverings and housings for electric consumer devices, Press Components SB has five heavy presses. Each of the five presses works in a different way and has a different size. The company currently has a contract to produce four products. 650 units of product P1, 550 units of product P2, 750 units of product P3, and 700 units of product P4 are required under the contract. TABLE Q2a shows the time (minutes) required for each product to be manufactured on each machine.

TABLE Q2b shows the historical record of defectives for the four items during the last year. Analyze the company's quality issues with appropriate TQM tools. Propose a quality-control plan to resolve the problems.

[Facilities Operation Management]

TABLE Q2a Product E P1 35 A 30 35 30 30 200 P2 P3 P4 Machine hours available Machine (time in minutes) B D 41 40 39 36 45 40 40 45 55 40 40 50 260 250 260 Profit per unit (RM) 25 30 35 30 42 40 50 270 TABLE Q2b Number of defects Percentage % 63 43.4 35 24.1 Defects Dimensional accuracy Fracture Defective materials Defective parts Operator errors Surface abrasions 25 17.2 10 7.0 7 4.8 5 3.5