<![CDATA[Quality issues in the painting process are critical because they can increase production costs and reduce operational efficiency. In this automotive painting industry, Line B recorded the highest reject rate in January 2025, reaching 59.2% of its total output. Small spot defects were identified as the most dominant type, accounting for 82.38% of all defective products, making them the primary focus of this study. This condition indicates inconsistencies in the process that need to be systematically analyzed. This study aims to identify the root causes of small spot defects in Line B using the Root Cause Analysis (RCA) method. The analysis involved collecting production data, identifying contributing factors through a Fishbone Diagram, and tracing the root causes using the 5 Whys method. The findings show two main causes: insufficient overlapping spray, which results in uneven paint application, and defective raw parts that passed the initial inspection stage. Based on these findings, improvement recommendations include revising work instructions related to painting techniques, enhancing operator accuracy through training, and improving the workflow and ergonomics of raw material inspection. Implementing these improvements is expected to reduce defect rates and strengthen the quality control system in the automotive painting process. Keywords: 5 Whys Analysis, Fishbone Diagram, Quality, Quality Control, Root Cause Analysis ]]>
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