Presentation on theme: "WP Inc. Case STUDY 3.1 Problem Solving Jonathan Stanley & Kari Eddings"— Presentation transcript:
1 WP Inc. Case STUDY 3.1 Problem Solving Jonathan Stanley & Kari Eddings Southwestern College Professional studiesDr. Michael corriere
2 Background WP Inc. is a manufacturer of small metal parts. Using customer designs they create tools, stamps, bends, and forms the metal parts; and deburrs, washes, and ships to customersMultiple reoccurring problems with automatic parts washerThe spray nozzles frequently clogging particlesThis causes time delays due to every part goes through the washerCritical aspect in the cleaning process with no alternative because of EPA regulations.There are a plethora of issues WP Inc. need to address with their manufacturing of metal parts. At the top of the list the automatic parts washer is the central hub that the whole process runs through. It cleans and scrubs all the dirt away like dishwashers do. The spray nozzles happen to cause problems cleaning the parts washer and cause this imperative system to shutdown. This causes ridiculously long delays in the quality process and must be resolved.
3 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 teamEstablish performance standards and measuresClearly state the problemOnce the problem is identified document and analyze the problemDetermine why, what are the issues, and the causesOnce all information is gathered develop plan of attackImplement, revise, troubleshoot, and evaluate the solutionAlways look to innovate and improve
4 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.
5 Flowchart New soap and heated water are put in tank Water is emptied YESNOIs waterdirty?CoilsheatwaterNODirty parts are placed in machinePartsarerunParts washer is turned onAre parts clean?Parts move to next stepYESEvaporation occurs; water and soap are added
6 Cause & Effect Materials Methods Nozzle Clogs Up People Machines Non-dissolvable soapLack of filter system between tank & nozzleEvaporation should occur at correct temperatureSoap & water solution clogs nozzleResidue build-up in the tankWhen tank drains new solution is put inIncreasing soap concentrationNozzle Clogs UpWasher has issues mostly in the afternoonOperator records daily problemsTank temperatureis too lowMore solution is added as fluids decreaseOperator needsProper trainingNo filtering systemTank is not cleaned often enoughPeopleMachines
7 Washer Nozzle Clogging Up Why - Why DiagramWhy do the nozzles not spray as they should?Why is the temperature not warm enough?Washer Nozzle Clogging UpWhy is the solution changed so often?Why is washing parts critical to the process?Why do washer tanks continue to break?
8 Resolution and Corrective Measures Stopping the clogging in the washer nozzlesResolve automatic parts washerRemove dirt and soap scum using hot waterReduce the delays in the washing operationQuality management and establishing teamResolve issues and customer service satisfaction
9 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.
10 New Model Process Flowchart Remove waterClean water is filtered in tank.Nozzles replaced, tank is cleaned, soap scum is washed out.YESAdd soap after soap scum is removed.Check tank, search for cleanlinessNORinse and repeat process to verify it worksNOWash accordinglyVerify all is good and process worksNozzle diameter is increased with smaller holesTurn parts washer on, replace partsYES
11 Why - Why Diagram Results Increased nozzle size for better washing capabilitiesCleared Washer NozzleMonitored soap intake for proper cleaningInstalled filtration system & pumpCorrected heating element for proper evaporation temperatureResidue build-up in tank has been cleared
12 Force-Field Analysis/Actions Driving ForcesIncrease nozzle size make more smaller holes, change parts, enhance washing operationResolving the issues above increases productivity, reduces delays, and less time wasted fixing the machinesSpray 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 ForcesTake offline 20 minutes a day to clean and use different cleanerResearch costs for new pump, establish budget to resolve problemMaximize resources, personnel, and suppliesTraining employees, change in process, procedural change, and documenting accordingly
13 ConclusionIncreasing 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.
14 ReferenceSummers, D. (2010). Quality/5e. Upper Saddle River, NJ: Prentice Hall.