1)  What and where (in the process) was a break-down in Mattel’s quality product control(s)?

2)  What actions were taken by Mattel to rectify the problem and, in your opinion, was that enough?

3) Using Exhibit 7 from Page 13 of the case, create a plot that shows number of recalls and the year(s) data.  Classify the recalls into Infant, Young Children and Older Children categories (your interpretation).  Show frequency of recalls under each category by year.  Hint:  Create a multi-column file.  Enter every recall, year, and assigned category.  Use PivotTables to do the analysis (counting and charting).  The more granular you get with base data, the more flexibility you’ll have in insights gathering and charting.

Additional Information: 

Mattel’s Response

In the August 14 product recall announcement, Mattel stated that it was improving its process to prevent the use of lead paint.  The company’s senior vice president of worldwide quality assurance said:

We have immediately implemented a three-point check system: First, we’re requiring that only paint from certified suppliers be used and requiring every single batch of paint at every single vendor to be tested.  If it doesn’t pass, it doesn’t get used.  Second, we are tightening controls throughout the production process at vendor facilities and increasing unannounced random inspections.  Third, we’re testing every production run of finished toys to ensure compliance before they reach our customers.  We’ve met with vendors to ensure they understand our tightened procedures and our absolute requirement of strict adherence to them.

The company also reviewed compliance with its rules regarding excessive levels of subcontracting, and notification of the use of subcontractors.  In addition, it planned to purchase many portable lead detectors for use in its own factories and those of its suppliers.