WP Inc.CASE STUDY 3.1

PROBLEM SOLVING

JONATHAN STANLEY & KARI EDDINGS

SOUTHWESTERN COLLEGE PROFESSIONAL STUDIES

DR. MICHAEL CORRIERE

Background

WP Inc. is a manufacturer of small metal parts.

Using customer designs they create tools, stamps, bends, and formsthe metal parts; and deburrs, washes, and ships to customers

Multiple reoccurring problems with automatic parts washer

The spray nozzles frequently clogging particles

This causes time delays due to every part goes through the washer

Critical aspect in the cleaning process with no alternative because of EPA regulations.

Problem Solving Statement/Steps

Need to figure out how to stop the clogging of the nozzles, resolve and fix the floating particles.

Establish a quality management improvement team

Establish performance standards and measures

Clearly state the problem

Once the problem is identified document and analyze the problem

Determine why, what are the issues, and the causes

Once all information is gathered develop plan of attack

Implement, revise, troubleshoot, and evaluate the solution

Always look to innovate and improve

Collective Brainstorming

In order to stops the clogging the spray nozzles need to be sprayed regularly. This will minimize the chance for floating particles to contaminate the clogged nozzles. This needs to be done with heated water so the particles do not settle at the bottom of the tank.

The quality management team will be Kari and JJ. Together we will establish conformity standards and measures to minimize problems and maximize performance.

The particles are severely slowing the process. It could be hard-water buildup, calcium, chips from the parts, paint chips, soap flakes, something by chemical reaction, or gravel dirt. The commonality is these can all be reduced/eliminated by keeping the nozzles clean, spraying frequently, and prevent time delays.

Then document the results, create a log book and track everything.

The nozzles are too big and too small at the same time. The soap scum keeps developing after two minutes.

Flowchart

Parts washer is turned on

Evaporation occurs; water and soap are added

Dirty parts are placed in machine

Parts are run

New soap and heated water are put in tank

Water is emptied

Parts move to next step

Is water dirty?

Are parts clean?

Coils heat water

NO

NO

YES

YES

Cause & Effect

Materials

Methods

Nozzle Clogs Up

MachinesPeople

Soap & water solution clogs nozzle

Residue build-up in the tank

Increasing soap concentration

Evaporation should occur at correct temperature

When tank drains new solution is put in

Lack of filter system between tank & nozzle

Non-dissolvable soap

Operator records daily problems

More solution is added as fluids decrease

Operator needs Proper training

Washer has issues mostly in the afternoon

Tank temperature is too low

No filtering system

Tank is not cleaned often enough

Why - Why Diagram

Washer Nozzle Clogging Up

Why do washer tanks

continue to break?

Why is washing

parts critical to

the process?

Why is the solution

changed so often?

Why is the temperature

not warm enough?

Why do the nozzles not

spray as they

should?

Resolution and Corrective Measures

Stopping the clogging in the washer nozzles

Resolve automatic parts washer

Remove dirt and soap scum using hot water

Reduce the delays in the washing operation

Quality management and establishing team

Resolve issues and customer service satisfaction

Brainstorming Results In order to stops the clogging the spray nozzles need to be

sprayed regularly. This will minimize the chance for floating particles to contaminate the clogged nozzles. Spraying every 12 hours.

The particles are severely slowing the process. The soap scum is the culprit. We made the nozzles larger in diameter, with smaller holes so less soap scum and particles develop and changed the cleaning solution more often.

A log was created and is noting every step along the way.

The soap scum was developing after two minutes and is now significantly better after our changes. We also added more water pressure to the pump to become more proficient.

New Model Process Flowchart

Add soap after soap scum is

removed.

Turn parts washer on,

replace parts

Wash accordingly

Nozzle diameter is

increased with smaller holes

Verify all is good and

process works

YES

NO

NO

YES

Rinse and repeat process to verify

it works

Check tank, search for cleanliness

Remove waterClean water is filtered in tank.

Nozzles replaced, tank

is cleaned, soap scum is washed out.

Why - Why Diagram Results

Cleared Washer Nozzle

Increased nozzle size for better washing

capabilities Monitored soap intake for proper cleaning

Installed filtration system &

pumpCorrected heating

element for proper

evaporation temperature

Residue build-up in tank has

been cleared

Force-Field Analysis/ActionsDriving Forces

Increase nozzle size make more smaller holes, change parts, enhance washing operation

Resolving the issues above increases productivity, reduces delays, and less time wasted fixing the machines

Spray water and clean more often.

Improve water infiltration system, use different pump with more pressure.

Most importantly with no delays or issues with parts, no soap scum buildup this means happy customers, more money for the WP Inc. and provides a PERMANENT fix.

Restraining Forces

Take offline 20 minutes a day to clean and use different cleaner

Research costs for new pump, establish budget to resolve problem

Maximize resources, personnel, and supplies

Training employees, change in process, procedural change, and documenting accordingly

Conclusion

Increasing the size of the nozzle, making the holes smaller, cleaning out the soap scum regularly, utilizing the soap properly and generating enough pressure to be adequate enough to clean with the new soap should resolve all possible issues of the soap buildup.

Also using heated water could cause the particles not to settle at the bottom of the tank and enhanced operating procedures with scheduled cleaning shifts should assist too.

This would appear to be both cost effective and advantageous to become more proficient and operate at full capacity. The quality management team can then take over from there and monitor accordingly.

Reference

Summers, D. (2010). Quality/5e. Upper Saddle River, NJ: Prentice Hall.