1. Case Study 3.1 WP Inc MGMT 580 – Quality Management and Statistics Group 3: Cody Groves, Bruce Kastner, & Heather Moore

2.  Manufacturer of small metal parts  Utilizes customer’s designs to create tools, stamps, bends then forms these parts  Also deburrs, washes, and ships the parts to the customers  Uses an automatic parts washer to wash small particles of dirt and oil from the parts which is a critical process in WP’s business  EPA no longer allows the use of a vapor degreaser using tricloroethane 1,1,1 WP Inc

3.  WP Inc has an issue with the spray nozzles clogging in the parts washer as parts are being washed  Occurs most often after the old cleansing solution has been drained from the tank and new solution put in Problem Statement

4.  What are the particles clogging the nozzles?  Hard-water buildup  Calcium  Chips from the parts  Paint chips  Soap flakes  Something due to a chemical reaction  Gravel, or dirt  Corrosion within the washer Brainstorming Results

5. Cause & Effect Diagram Soap Build-up Machinery Heated Tank Evaporation Filtering System Materials Soap Concentration Too high Written Procedures Plant Manager Engineer Supervisor Machine Operator Time Delivery Method Drained Tank New Solution added Too Low Temp too low Temp too High Man Method Cleaning Process Free Floating Particles Nozzles Temperature Chart

6.  Driving Forces  Evaporation  Tank Temperature  Soap Concentration  Clogged Nozzles  Restraining Forces  Employee Training  Equipment Design Force-Field Analysis

7.  Actions 1.Evaporation cannot be eliminated, however, when the operator notices evaporation taking place; rather than adding more of the soap solution, he/she should add plain water instead in order to keep the soap mixture at the proper concentration level, 2.Testing has shown that the soap concentration works better when the tank is at an elevated temperature. Operator should monitor tank temperature and ensure it remains above an acceptable temperature level for maximum breakdown of soap particles 3.The level of soap concentration can be monitored and maintained by suing methods described above 4.The system does not currently have a filtration system between the tank and the nozzles; a design change would allow for a filtration system to be installed that would filter out hardened soap particles and prevent them from reaching the nozzles. This process would require additional work by the operator who would check the filters periodically throughout the day, however this would have less impact on the business compared to shutting down to remove and clean the nozzles Force-Field Analysis, cont…

8. After reviewing the brainstorming results, cause-and-effect diagram, and the notes made by the operator, management has determined that the first action item is to have a product design specialist begin working on revisions to the machinery that would allow for temperature regulation, sight glass which allows for the real monitoring of soap concentration, and the installment of a filtration system to prevent soap from reaching the nozzles. While this could take some time, in the interim operators will be trained to regularly monitor the soap concentration level and tank temperature; making proper adjustments as necessary to maintain the concentration level and temperature for optimal performance. Nozzles will also be removed between shifts and inspected to ensure they stay clear of debris and operate at maximum efficiency. Management is positive that by implementing these changes the overall quality and customer satisfaction will be heightened with minimal cost, or loss, to the company. Management Summary