Michael Chen
Quality Management Expert & Six Sigma Master Black Belt
About Michael
Michael Chen is a globally recognized quality management expert with over 22 years of experience solving critical manufacturing quality crises. As a Six Sigma Master Black Belt and Toyota Production System specialist, he has led transformational quality improvement initiatives across automotive, aerospace, pharmaceutical, and electronics industries.
His expertise in root cause analysis methodologies, particularly 5 Whys and Fishbone diagrams, has helped Fortune 500 companies achieve breakthrough improvements in quality, safety, and operational excellence. Michael has personally trained over 2,000 quality professionals and led projects resulting in cost savings exceeding $500 million.
A passionate advocate for systematic problem-solving, Michael founded 5whysexample.com to democratize access to professional root cause analysis tools and share best practices with quality professionals worldwide.
Areas of Expertise
Methodologies
- • Root Cause Analysis (5 Whys, Fishbone)
- • Six Sigma (DMAIC, DFSS)
- • Toyota Production System (TPS)
- • Lean Manufacturing
- • 8D Problem Solving
- • FMEA (Failure Mode Effects Analysis)
Industries
- • Automotive Manufacturing
- • Aerospace & Defense
- • Pharmaceutical & Medical Devices
- • Electronics & Semiconductors
- • Food & Beverage Processing
- • Healthcare Operations
Certifications & Education
Six Sigma Master Black Belt
American Society for Quality (ASQ), 2008
ASQ Certified Quality Engineer (CQE)
American Society for Quality, 2005
Lean Manufacturing Certification
Toyota Production System Institute, 2006
MBA, Operations Management
MIT Sloan School of Management, 2003
BS, Industrial Engineering
University of California, Berkeley, 1998
Career Highlights
Global Quality Director
Fortune 100 Automotive Manufacturer | 2015-2020
Led global quality transformation initiative across 45 manufacturing plants. Reduced defect rates by 73% and warranty claims by $180M annually through systematic root cause analysis and preventive action implementation.
Six Sigma Master Black Belt
Aerospace & Defense Contractor | 2010-2015
Directed enterprise-wide Six Sigma program for 12,000+ employees. Certified 150+ Black Belts and Green Belts. Delivered $420M in verified cost savings through DMAIC and root cause analysis projects.
Quality Engineering Manager
Medical Device Manufacturer | 2005-2010
Established comprehensive CAPA system achieving 100% FDA compliance. Implemented 5 Whys and Fishbone methodologies across R&D and manufacturing, reducing product recalls by 92%.
Publications & Speaking
Selected Publications
- • "Advanced Root Cause Analysis in Manufacturing" - Quality Progress Magazine, 2022
- • "AI-Enhanced Problem Solving: The Future of RCA" - ASQ Annual Conference, 2023
- • "5 Whys vs. Fishbone: When to Use Each Method" - Lean Enterprise Institute, 2021
- • "Building a World-Class CAPA System" - Quality Digest, 2020
Conference Speaking
- • ASQ World Conference on Quality & Improvement (Keynote Speaker, 2023)
- • International Manufacturing Technology Show (Panel Expert, 2022)
- • Lean Six Sigma World Conference (Workshop Leader, 2021, 2023)