Presentation on theme: "WP Inc: spray nozzle blues"— Presentation transcript:
1 WP Inc: spray nozzle blues MGMT 580 FINAL PROJECT: S. BATCHELDERWP Inc: spray nozzle blues
2 What’s the problem? Spray nozzle on the parts washer is clogging Integral part of the manufacturing processEach part manufactured goes through washerCreates time delaysOnly alternative for cleaning parts to maintain quality system
3 The causes could be… Nozzle installed incorrectly Debris in water causing clogFrom water in tankFrom water fed through lineBuildup from hard waterDebris from partsSoap interactionMalfunction in nozzleMineral deposit
4 The Fishbone: Cause & Effect. MACHINE PROBLEMSWATER PROBLEMSWater in tank not optimal temperatureNo filtersystemMalfunctionEvaporation causes levelvariationOperator ErrorCLOGGEDWATERNOZZLEResidue in tankSoap/waterMixtureFlakesSOAP PROBLEMS
5 Mitigate the causes. Machine problems Operator training Investigate adding filtration systemAudit of parts and performance
6 Mitigate the causes. Soap and water problems Operator training Revise operational processesExplore alternative brands of cleaning solutionTemperature control systemSupply fill water to counter evaporation
7 Force Field Analysis 1. Operator Training DRIVING FORCES RESTRAINING FORCESSimple process adjustmentsMotivationLow costsolutionInconsistentHigherMoraleTime to implement
8 Force Field Analysis 1. Overhaul Machinery/ New Equipment DRIVING FORCESOverhaulMachinery/NewEquipmentRESTRAINING FORCESBetter technology (filter, temp control)ExpensiveProcess better, more reliableCompatibilitySpend money to save moneyLearning curve
9 Force Field Analysis 1. Fill water/ New brand of cleaning solution DRIVING FORCESFill water/New brand ofcleaningsolutionRESTRAINING FORCESAdded steps to processCould belower costOpportunity for new partnershipAvailabilityAdditional cost to implement
10 Follow up the Force Field. The low cost option is to correct the temperature control issueOR explore alternatives to cleaning solution that may dissolve at lower tempBoth would involve an element of incorporating clean fill water to alleviate evaporationLast resort is new equipment or modifying existing equipment for cost reasons
11 Corrective actions could be… Incorporate a fill water system AND…Operator trainingMaintain temperatureUse water only to fill after evaporationInvestigate alternate brand of cleaning solution or adding a filtration option for existing machine
12 Corrective Action Plan ISSUESOLUTIONTIMEFRAMESUCCESSEVALUATIONPERSONRESPONSIBLEWater temp. not optimalTrain ops to monitor and adjust as needed2 weeks to reach all operatorsConsistent results in temp samplesIf success fixes problem, completed.Ops Supervisors/ManagerSolution used to fill tank when evaporation occursImplement clean fill- water solutionAfter results of item 1 determinedSoap deposits reduced in tankAbove plus facilities.No filtering systemExplore options to add systemAfter results of items 1 and 2 determinedFiltering system installedOperations supervisor, purchasing,controller
13 Implementing the CAP…Each action is determined by success or failure of previous actionAction 1 (training):Document what process is for achieving and maintaining correct temp range and acceptable variations.Establish training schedule for all operators to educateTwo weeks should cover all shifts/employees
14 Implementing the CAP… Action 2 (clean fill water) Evaluation and testing of water supply to ensure no negative reaction with cleaning solutionDetermine water delivery system and storage methodsEstablish guidelines and process on when and how to use the clean fill waterAny additional process changes to include this step in washing parts
15 Implementing the CAP… Action 3 (install filter) Determine if existing machine can be fitted with filterIf so, find cost, installation procedure and downtime expected for machineAdditional training, process steps may be neededIf unable to modify existing machine, explore purchasing new machine
16 Follow up. Action 1 (training): Sample water temp regularly Compare with instances of nozzle clogging before implementation of actionIf action remedies problem, further analysis could be done to determine the exact temp at which the nozzle starts to experience clogging
17 Follow up. Action 2 (clean fill water): Sample water in tank regularly to determine presence of particulate matterGather data to further evaluate effects of fill water temp and volume on cleaning solutionEvolve process for water storage and delivery as needed to increase efficiency in process
18 Follow up. Action 3 (install filter): Determine best option for modifying or purchasing new equipment, contact manufacturer of machineEvaluate efficiency and any changes in initial costs as well as total cost of ownership of this action after implementation
19 ConclusionAction 1 is very low cost, low impact solution to try that has seems to have a high probability of working.Temp affects both the functionality of the machine as well as the soap used in the solution.The build up of non-dissolved soap is prime suspectTraining the operators and making small adjustments to operational process could be solution.
20 ConclusionThe fill water option is still lower cost, but involves a lot of testing for compatibility and best practices for introducing a new variable to the process.This solution would also add to the operational process, but could easily be implemented with the proper instruction.The next step up would be to modify the machine, or take it a step further and replace it.
21 ConclusionAdding a filter could be expensive, so could replacing the machine. Additionally, the time lost and any additional training with new equipment could be taxing. In the long run, it could result in a more efficient process.A quick search shows that the machine type described could retail for around $8,000. A considerable chunk of money, but not usually a back-breaker.With a three-tiered action plan, there is no pressure to spend a lot of money right away, the first two options are the easier ones.
22 References“Cause & Effect Diagram.” (2014). Retrieved from TC aspx“Force Field Analysis.” (2014). Retrieved from“Spray aqueous parts washers.” Retrieved from kleen.com/products-services/parts-cleaning-technologies/aqueous-parts- washer/spraySummers, D. (2010). Quality/5e. Upper Saddle River, NJ: Prentice Hall.“Writing an effective corrective action plan.” (2014). Northwestern University Research [online]. Retrieved from