Scaling quality excellence: a digital quality management system for Yangon tyre plant B

This business consulting project addresses a critical operational vulnerability at Yangon Tyre's Plant B manufacturing facility: the organization's dependence on a single part-time quality management expert, Mr. Wu, whose tacit knowledge and problem-solving capabilities have been instrumental in achieving significant quality improvements. Through a mixed-methods research approach combining qualitative stakeholder interviews with quantitative production data analysis, this study examines the current state of quality management operations, identifies systemic vulnerabilities, and proposes a comprehensive Digital Quality Management System (DQMS) solution. The research involved in-depth interviews with eight key stakeholders across multiple organizational levels, from senior management to operational staff, supplemented by analysis of eight months of production data (January-August 2025) comprising 328,343 tires. The findings reveal that while Mr. Wu's interventions have reduced B-grade defect rates from peaks of 10% to a consistent average of 1.58%, and reject rates from over 4% to 0.51%, these achievements remain vulnerable to his potential unavailability. The proposed DQMS solution comprises four integrated modules: (1) Real-Time Quality Monitoring Dashboard, (2) Knowledge Management Repository, (3) Predictive Analytics Engine, and (4) Automated Reporting System. The implementation framework follows a 12-month phased approach aligned with Kotter's change management model, requiring a total investment of $63,470 with projected annual benefits of $117,500, yielding a 185% three-year ROI and 18-month payback period. This study contributes to both academic literature on quality management digitalization in emerging market manufacturing contexts and provides practical guidance for organizations seeking to transform expert-dependent quality systems into sustainable, technology-enabled operations.