1. WP Inc.: Faulty Spray Nozzles
MGMT580: Quality Management & Statistical Analysis Final Project
Michael S. Clever

2. Overview: WP Inc.
WP Inc. is a manufacturer who designs small metal parts utilizing a customer’s designs.
Creates the tools, stamps, bends, and forms metal parts
Deburrs, washes, and ships parts to the customer
WP Inc. utilizes an automatic washer for the parts-washing cycle.
Parts-washing operation is a critical aspect of WP Inc.’s quality process
WP Inc., a manufacture of custom small metal parts, has discovered a problem with their automatic parts washer machine that is used for washing metal parts. Since EPA regulations prevent WP Inc. from utilizing a vapor degreaser (that uses tricloroethane), the parts-washing operation is a critical part of the organization’s quality process (Summers, 2010, p. 100).

3. The Machine: Automatic Parts Washer
The automatic parts washer removes small particles of dirt and oil from custom metal parts.
Washer resembles a dishwasher
Washer composed of spray nozzles, a parts basket, a hose, the water holding tank, and a pump
Integral part of the parts-washing process.
Only alternative for cleaning parts due to EPA regulations
The automatic parts washer operates in similar fashion to a dishwasher, with components such as nozzles, a parts basket, hose, water holding tank, and pump. Without the automatic parts washer, the metal parts cannot be appropriately cleaned before being shipped to customers.

4. The Process: Parts-Washing
The automatic parts washer operates in similar fashion to a dishwasher, with components such as nozzles, a parts basket, hose, water holding tank, and pump. Without the automatic parts washer, the metal parts cannot be appropriately cleaned before being shipped to customers.

5. The Problem Solving Process
Plan
Recognize a problem exists
Form an improvement team
Develop performance measures
Clearly define the problem
Document and analyze problem/process
Determine possible causes Do
Identify, select, and implement solution
Study
Evaluate solution
Act
Ensure performance
Continuous improvement
Plan Do
Study
Act
To determine why the spray nozzles are causing consistent issues with the automatic parts washer, we will utilize the problem solving process. The problem solving process is broken down in to four phases: plan, do, study, and act. We will look in to each phase in detail.

6. The Problem: Nozzle Behaviors
Clogged nozzles restrict the flow of soap- and-water solution, which eventual shuts the automatic parts washer down.
Clogged nozzle occurrences:
Seven times in one month
Two midday
Five at end of day
Inspection of clogged nozzles yields:
Small particles in orifices of nozzles
Particles white and flake-like in appearance
It has been previously discovered that the spray nozzles are becoming clogged with unknown particles, causing the shut down of the automatic parts washer. When the nozzles are clogged, the clogging restricts the flow of the soap-and-water solution (the cause of the machine’s shut down). When this process was tested, the operator reported that the machine shut down seven times in a month’s time frame. Two of those shut downs occurred midday, while the rest occurred at the end of the day. The particles lodged in to the orifices of the nozzles were white and flake-like in appearance.

7. Brainstorming: What are the Causes?
Hard-water buildup
Coil malfunction (inaccurate water temp)
Soap flakes
Part chips
Improper system maintenance
Incomplete evaporation cycle
Chemical reaction
Based on the information we have so far, we can come up with a list of causes of the clogged nozzles. Some of these causes could be from system malfunctions, processes in the cycle, or even chemical reactions.
Calcium
Gravel or dirt
Nozzle malfunction
Pump malfunction
Paint chips

8. The Problem Redefined
Spray nozzles on the automatic washer consistently cause recurrent problems during the parts-washing process from being frequently clogged with unknown particles, such as:
Hard-water or calcium buildup
Paint or part chips
Soap flakes
Gravel or dirt particles
The recurrent problems could also be a chain reaction from:
Nozzle malfunction
Coil malfunction
Pump malfunction
Improper system maintenance
Incomplete evaporation cycle
Now that we have brainstormed a list of probable causes, we can redefine our problem statement. The spray nozzles are frequently clogged with unknown particles, such as hard-water buildup, calcium, paint/part chips, soap flakes, or gravel/dirt. The recurrent problem could also be from system malfunctions, improper system maintenance, or an incomplete evaluation cycle in the parts-washing cycle.

9. Honing in on the Problem
Spray nozzle problem occurs most often when the old cleansing solution is drained from the automatic parts washer, and replaced by the new cleansing solution.
The water holding tank should be free of any particles.
When nozzles are removed and inspected after running a few cycles, the nozzles are clogged with particles.
Further inspection concludes that the particles are soap particles.
There is a layer of hard soap at the bottom of the water holding tank.
Why is the bottom of the tank covered with a layer of hard soap?
Further investigation of the problems results in finding that the problem almost always occurs when a new cleansing solution is added to the water holding tank after successful draining of the old, dirty cleansing solution. When the nozzles are inspected after a few cycles, it is discovered that the lodged particles are soap. Now we must determine why the bottom of the tank is covered with a layer of hard soap.

10. Cause-and-Effect Diagram: Soap Buildup
Clogged Nozzles
Water Tank Problems
Water Problems
Soap Problems
Increased soap concentration
Soap-and-water solution
No filtration
Free floating particles
Low temperatures
System parts malfunctions
Soap-and- water solution
Hard-water buildup
Evaporation process
The cause-and-effect, or fishbone, diagram helps to display to potential causes for a problem (effect) (Simon, n.d.). Here we see potential causes resulting from water problems, soap problems, and water tank problems.

11. Cause-and-Effect Diagram: Analysis
Soap concentration needs to be measured before adding more soap-and- water solution to the automatic parts washer throughout the day.
The lack of a filtration system between the tank and spray nozzles in the automatic parts washer is causing more problems than necessary in regards to soap and hard-water buildup.
A system should be implemented and utilized to monitor water temperature in the automatic parts washer to ensure proper dissolution of soap concentration in order to eliminate free floating soap particles.
Analysis of the cause-and-effect diagram provides us with a few suggestions to resolve to problem. The first thought would be that the soap concentration needs to be measured before being added to the automatic parts washer throughout the day. Also, the lack of filtration system is causing unnecessary water and soap buildup. Lastly, a system to monitor water temperature in the washer to ensure proper dissolution of the soap is necessary.

12. Force-Field Analysis: Clogged Nozzle Reduction
Driving Forces
Increased productivity
Reduction in time delays
Quality improvement
Restraining Forces
1. Expenses (filtration)
2. Consistent monitoring of water temperatures and soap concentration
Actions
Find a cost-effective way to develop and install a filtration system in the automatic parts washer.
Implement and utilize a system for monitoring water temperature and soap concentration.
Through a force-field analysis, we know that the driving forces to eliminating clogged nozzles would be increased productivity, a reduction in time delays, and quality improvement. The restraining forces are expenses for the filtration system and consistent monitoring of water temperatures and soap concentration.

13. Plan of Action: Eliminating Clogged Nozzles
Design and install a filtration system to exist between the water holding tank and spray nozzles.
Elimination of soap particles clogging the spray nozzles
Develop a method to accurately monitor soap concentration and water temperature level.
Full dissolution of soap concentration, preventing soap buildup on the bottom of water holding tank.
Eliminating the recurrent problem of clogged nozzles in the automatic parts washer will lead the way to a variety of improvements for WP Inc.
Increased productivity from a reduction in time delays
Quality improvement in the manufacturing of metal parts
The plan of action to eliminate clogged nozzles includes two action steps. The first is to design and install a filtration system for the water holding tank and spray nozzles, which will eliminate soap particles from clogging the spray nozzles. The second, develop a method to accurately monitor soap concentration and water temperature, will allow for full dissolution of soap concentration. Following this action plan will lead to a variety of improvements for WP Inc., such as increased productivity from a reduction in time delays and quality improvement in the manufacturing of metal parts.

14. Plan of Action: Evaluation
The automatic parts washer filtration system will reduce soap residue on the bottom of the water holding tank, which also eliminates floating soap particles when new cleansing solution is added.
Accurate water temperatures will result in better dissolution of soap concentration.
Monitoring soap concentration levels (soap-to-water ratio) will also reduce floating soap particles.
Here, the plan of action is evaluated to show how the action steps will help eliminate the recurring problem of clogged nozzles.

15. Plan of Action: Consistent Follow-Up
Establish continuous monitoring of suggested solutions.
Soap-to-water solution ratio
Water temperature levels for soap dissolution
Develop a training plan for current and future employees to ensure process consistency.
Manuals detailing accurate soap concentration and appropriate water temperature.
Consistently evaluate processes and adjust, as needed.
The plan of action will need to be consistently monitored to ensure the problem is corrected. This can be done through monitoring soap-to-water solutions and water temperature levels, as well as developing a training plan for current and future employees. If the processes need to be adjusted, they should be.

16. Management Summary
WP Inc. discovered a recurrent problem with the spray nozzles in the automatic parts washer that consistently caused the washer to shut down.
The nozzles are clogged from an unknown particle, preventing appropriate washing of the metal parts.
Through further investigation and questioning of the operator monitoring the parts-washing process, a more accurate problem was discovered.
The spray nozzles are clogged almost always after a new cleansing solution replaces the old cleansing solution drained from the water holding tank.
Lastly, we have the management summary on the next three slides that describes the problem solving process and how it was used to eliminate the problem with the clogged nozzles in the automatic parts washer.

17. Management Summary
Testing the parts-washing operation cycle after adding new cleansing solutions discloses that particles clogging the spray nozzles are soap.
The problem-solving team drains the water holding tank and discovers soap buildup at the bottom.
Because the automatic parts washer does not have a filtration system, the buildup turns in to floating particles when new cleansing solution is added.
Utilizing a cause-and-effect diagram helps to pinpoint necessary solutions to eliminating clogged nozzles:
A filtration system from water tank to spray nozzles
A system to monitor soap concentration and water temperature levels

18. Management Summary
Creating a force-field analysis yields the need to find a cost-effective way to develop and install a filtration system in the automatic parts washer and implement and utilize a system for monitoring water temperature and soap concentration.
With successful implementation of the plan of action, WP, Inc. can eliminate the recurrent problem of clogged nozzles in the automatic parts washer, leading the way for increased productivity and quality improvement.

19. References
Simon, K. (n.d.). The cause and effect (a.k.a. fishbone) diagram. Retrieved on April 1, 2016 from effect/cause-and-effect-aka-fishbone-diagram/.
Summers, D.C.S. (2010). Quality (5th ed.). Upper Saddle River, NJ: Pearson Education.