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 forms the 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. 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.

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 New soap and heated water are put in tank Water is emptied YES NO Is water dirty? Coils heat water NO Dirty parts are placed in machine Parts are run Parts washer is turned on Are parts clean? Parts move to next step YES Evaporation occurs; water and soap are added

Cause & Effect Materials Methods Nozzle Clogs Up People Machines Non-dissolvable soap Lack of filter system between tank & nozzle Evaporation should occur at correct temperature Soap & water solution clogs nozzle Residue build-up in the tank When tank drains new solution is put in Increasing soap concentration Nozzle Clogs Up Washer has issues mostly in the afternoon Operator records daily problems Tank temperature is too low More solution is added as fluids decrease Operator needs Proper training No filtering system Tank is not cleaned often enough People Machines

Washer Nozzle Clogging Up Why - Why Diagram Why do the nozzles not spray as they should? Why is the temperature not warm enough? Washer Nozzle Clogging Up Why is the solution changed so often? Why is washing parts critical to the process? Why do washer tanks continue to break?

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 Remove water Clean water is filtered in tank. Nozzles replaced, tank is cleaned, soap scum is washed out. YES Add soap after soap scum is removed. Check tank, search for cleanliness NO Rinse and repeat process to verify it works NO Wash accordingly Verify all is good and process works Nozzle diameter is increased with smaller holes Turn parts washer on, replace parts YES

Why - Why Diagram Results Increased nozzle size for better washing capabilities Cleared Washer Nozzle Monitored soap intake for proper cleaning Installed filtration system & pump Corrected heating element for proper evaporation temperature Residue build-up in tank has been cleared

Force-Field Analysis/Actions Driving 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.