How can Procter & Gamble address the 15% increase in manufacturing defects for Gillette razor blades at its Boston plant over the last month?

Introduction

Addressing the 15% increase in manufacturing defects for Gillette razor blades at Procter & Gamble's Boston plant over the last month requires a systematic approach to identify, validate, and resolve the root cause. This analysis will follow a structured framework to thoroughly investigate the issue, considering both immediate and long-term implications for P&G's production quality and overall business performance.

Step 1

Clarifying Questions (3 minutes)

• Looking at the timing, I'm thinking this could be related to recent changes. Have there been any modifications to the manufacturing process or equipment in the past 1-2 months?

Why it matters: Recent changes often correlate with sudden performance shifts. Expected answer: Yes, there was a new blade coating process implemented. Impact on approach: If confirmed, we'd focus on the new process and its integration.

• Considering the specificity of the issue, I'm curious about the defect types. Can you provide a breakdown of the most common defects we're seeing in this 15% increase?

Why it matters: Different defect types point to different root causes. Expected answer: Uneven blade edges and inconsistent coating are the main issues. Impact on approach: This would guide our investigation towards specific manufacturing stages.

• Given the magnitude of the increase, I'm wondering about quality control. Has there been any change in the QC process or personnel in the last month?

Why it matters: QC changes could explain both real increases and false positives. Expected answer: No significant changes to QC processes or staff. Impact on approach: If confirmed, we'd focus more on production rather than detection issues.

• Thinking about external factors, has there been any change in raw material suppliers or the quality of incoming materials?

Why it matters: Input quality directly affects output quality. Expected answer: No changes in suppliers, but there was a new batch of steel received. Impact on approach: This would prompt an investigation into material quality and consistency.