AUTOMATIC PARTS WASHER: PROBLEM ANALYSIS

BEN BROXTERMANMBA STUDENT

SOUTHWESTERN COLLEGEMGMT 580, SUMMER 2012

WP Inc.

Background of Problem

WP, Inc. manufactures small metal parts Process includes: creating tools, stamping, bending,

and forming metal parts, deburring, washing, and shipping parts

Recurrent problems with parts washer Spray nozzles clog with particles frequently Causes time delays Critical part of process No alternative method for cleaning parts before

shipping

Process Flowchart

New soap and water are put

in tank.

Parts washer

is turned on.

Evaporation occurs; water and soap are added

Coils heat water. Dirty

parts are placed in machine.

Parts are run.

Are parts clean?

Parts move

to next step.

Is water dirty?

Water is emptied.

YES

NO

NO

YES

Problem Statement

Parts washer machine downtime must be reduced by at least 50% in the next

2 months.

Brainstorming: Potential Causes

• Exposure to dirt/particles from manufacturing process

• Water only changed when dirty

• Increasing concentration of soap from cycle of evaporation & replenishment with additional water & soap

• Soap dissolves best in higher-temp water

• Evaluation of “dirty” water is subjective

• Lack of more specific instructions for workers

• Nozzles small, clog easily

• Water not heated constantly

• Lack of filtration system

Cause & Effect

MaterialsMethods

PeopleMachines

Clogging nozzles

Environment

Water only changed when dirty

Increasing soap concentration

Exposure to particles

Soap dissolves best at higher temps

Evaluation of when water is “dirty” is subjective

Instructions for workers vague

Nozzles small

Water temp fluctuates

No filtration system between tank & nozzles

Diagram analysis

Water is only changed when it is noted to be “dirty” Assessment is subjective Water may contain more precipitate than is visible

Water heating occurs only at beginning of cleaning cycle. Soap used dissolves best at higher temperatures, may not be

dissolving properly. Addition of more soap and water when evaporation is noted

= high concentrations of soap, can no longer remain in solution.

Lack of filtration system = precipitate build up in nozzles.

Corrective Actions

Install filtration system between tank and nozzles to reduce amount of precipitate which reaches nozzles

Perform routine maintenance & cleaning of parts washer to control amount of build-up

Change operation processes to reduce negative strain on machinery and parts More frequent, scheduled water changes Maintain higher water temperature to allow more complete

dissolving of soap

Train staff operating parts washer on new processes as well as warning signs of precipitate build-up

Driving ForcesDriving Forces Restraining ForcesRestraining Forces

Perform routine machine cleaning & maintenance to keep nozzles clear of build-up

Install filtration system between tank & nozzles to reduce amount of precipitate that reaches nozzles

Change process to ensure more consistent machine performance

Downtime for upgrades to machine

Additional employee time needed for machine maintenance

Increased cost of supplies & operation More water, soap,

electricity

Force Field Analysis

Force-Field Analysis: Actions

Identify lower-volume times when machine can be taken offline for filtration system install.

Examine staff training and scheduling for those operating parts washer. Change hours of shift or add additional staff and shifts

for machine maintenance

Adjust budget to account for increased costs of operation.

New Process Flowchart

New soap added when

water reaches desired

temperature.

Parts washer

is turned on.

Coils heat water, are kept on to keep

temperature consistent.

Dirty parts are placed in machine.

Parts are run.

Are parts clean?

Parts move

to next step.

Is water dirty or used for 5 cycles?

Water is emptied.

YES

NO

NO

YES

New water is put in tank.

Nozzles and tank are cleaned,

precipitate washed out.

Coils kept on to keep water temperature consistent.

Follow Up

To ensure that actions taken produce positive results, the following steps will be taken: Track machinery downtimes before and after changes

are implemented to ensure that the changes have a positive effect

Implement process changes as part of ongoing training of new and existing staff

Account for additional productivity resulting from decreased parts washer downtime to ensure that additional costs related to operation and supplies are mitigated by increased revenue

Reference

Summers, D.. (2010). Quality (5th ed.). Upper Saddle River, NJ: Prentice Hall.