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Group 3’s Presentation for WP Inc.
Kirk BaringerSabrina Hoffman
Hanna Spicer
Problem-Solving Steps Plan
1. Recognize a problem exists2. Form a quality improvement team3. Develop performance measures4. Clearly define the problem5. Document and analyze problem/process6. Determine possible causes
Do7. Identify, select, and implement the solution
Study and Act8. Evaluate the solution9. Ensure permanence10.Continuous improvement
1. Recognize A Problem Exists
WP Inc. is a manufacturer of small metal parts based on the designs of their customers
WP creates, deburrs, washes, and ships the parts WP is currently encountering a problem with its automatic parts washer The recurring problem involves the spray nozzles which get clogged with small
particles resulting in the washer shutting down The washer shutting down has resulted in delays There is no alternative method to wash parts that meet EPA regulations After interviewing the washer operator the following was discovered
Operator has monitored process and recorded the behavior for about a month For a significant portion of time nozzles do not spray as freely as required On seven occasions nozzles have clogged completely Two of these clogs happened midday Remainder of these clogs occurred at the end of the day The nozzles did not clog in the morning Each time nozzles clogged the operator took them out to inspect them Appears that small particles become clogged in the tiny orifices of the nozzles These small particles appear to be white and flake like when dry
2. Form A Quality Improvement TeamMembers of Group 3
Kirk Baringer Master Sergeant and Noncommissioned Officer in Charge in the U.S. Air
Force Working on Masters of Science in Management
Sabrina Hoffman Military Spouse and Mother Working on Masters of Science in Management
Hanna Spicer Director of Academics at the U.S. Department of Education Working on Masters of Business Administration
2. Form A Quality Improvement TeamGroup Three Goals and Ground Rules
Goals Follow the steps to effective problem solving in order to find a solution
to the existing problem Prepare a presentation describing the problem solving process Present the solutions or outcomes to the problem solving process Follow up on the results of the problem solving process
Ground Rules All members must participate Responsibilities and duties must be fairly distributed Mutual respect for group members must be maintained at all times Each member’s inputs are just as important and valuable as the next
3. Develop Performance Measures
1. Eliminating clogs in the parts washer nozzles
2. Number of times the machine washer shuts down
3. Delays in the pats-washing operation
4. Delays in overall parts process
5. Quality of finished parts
6. Overall customer satisfaction
4. Clearly Define The ProblemBrainstorming Identity of Small Particles
Kirk Small metal particles coming off the pieces Minerals in the water Soap used in cleaning the parts
Sabrina Corroded hose Source water may be unfiltered and introducing sediment or creating had/soft water Paint chips from the parts Paint chips from the automatic parts washer (assuming that it is not stainless steel) Water to soap ration may be inaccurate (human error/machine error) Poor soap quality may result in insoluble soap particles Water is not changed enough or according to schedule
Others Hard-water buildup Calcium Chips from parts Paint chips Soap flakes Something caused by a chemical reaction Some type of gravel or dirt
4. Clearly Define The ProblemStatement of Problem
1. Quality is of upmost importance to WP Inc., and the parts-washing operation is a critical aspect of WP’s quality assurance process. The proper functioning of this parts-washing operation is essential in ensuring parts are ready for shipment to the customer without delay.
2. Though the parts-washing operation is not the most time-consuming or important operation it has been identified as the most troublesome. The spray nozzles of the automatic parts washer continue to get clogged with small particles. These clogs force the automatic parts washer to shut down which results in delays in the parts-washing operation. This ultimately results in delays in shipping of finished parts to the customer.
3. Customers expect their parts to arrive on time as promised, and if these promises are not met the customer will look elsewhere for their parts. If a solution can be found to the problem WP Inc. can continue to provide quality parts, on-time, and as promised. A company is only as good as the quality of its products and the promises they stand by.
5. Document And Analyze Problem/ProcessFurther Background of Problem
Problem occurs most often after cold cleansing solution has been
drained from the tank and new solution put in
Tests were conducted in which new cleansing solution was put in the
tank
Washer was ran for only two minutes
Nozzles were removed and inspected
Nozzles collected many particles
The particles were identified as soap particles
Tank was drained
Bottom of tank found to be coated with a layer of hard soap
Current Process Flowchart
Evaporation
occurs; water and soap are added.
Parts washer is
turned on.
Dirty parts are placed in machine.
Parts are run.
Are parts clean?
Parts move
to next step
Is water dirty?
Water is emptied.New soap and
water are put in tank.
Coils heat
water.
YES
YES
NO
NO
Automatic Parts Washer
6. Determine Possible CausesAffinity Diagram
Buildup of Soap
Water-Too much evaporation results in lower water levels-When water evaporates this increases the concentration of soap in the solution-This could result in soap settling on the bottom
Too Much Soap-Soap cannot be dissolved in the water-Adding too much soap could result in excess soap settling on bottom-Too much soap results in an inconsistent solution
Operating Procedures-Adding too much soap-water solution-Operator might not be trained-Procedures might need updated-Might not be following procedures correctly
Cleaning-Stirs up the soap the has settled-Soap becomes free-floating-Soap ends up trapped in nozzles-Is the tank cleaned according to schedules
Water Tank-Water temps have been too low-There is no filter installed
SOAP BUILDUP CAUSE AND EFFECT CHART
Soap build up on tank bottom
Hose
Clogged
Too small
Crimped
Operator
Adding too little water Not following
schedules Lack of training on written procedures
Water Tank
Temp too low to dissolve soap
Temp too high causes chemical reaction
No filter system
Soap
Inconsistent solution
Water
Water addition schedule No S
chedule
Hard water
Improper water flow
Water level indicator incorrect
Schedule not follow
ed
Cleaning Methods
Tank not completely rinsed/drained
Cleaning causes disturbance in soap particles in tank
Cleaning Schedule
No S
chedule
Schedule not follow
ed
Part washer nozzles are
clogging.
Check washer tub for
damaged paint surface.
Is washer tub stainless
steel?
NO
Check washer
tub.
Check water
supply. YES
Compare paint flakes to
particles in nozzle.
Is the painted surface
damaged?
NO
YES
Is water hard?
YES
Compare particle
buildup to hard water buildup.
Does source water have sediment?
Examine used water for metal and dirt fragments from parts.
NO
NO
Compare particle
buildup to water
sediments
Is water to soap ratio correct?
Check soap to water
ratio.
Is water temperature
correct?
NO
Test flakes to determine if they are soap residue.
Check water temperature.
NO
YES
YES
Is part sediment the same as sediment
blocking nozzle?
NO
7. Identify, Select, and Implement The SolutionIdentify
Potential Solutions
Installing a filter system to tank
Changing operating procedures
Changing cleaning procedures
Changing type of soap used
7. Identify, Select, and Implement The Solution
SelectChanging Operating Procedures
Though water might evaporate is it really necessary to add more
soap-and-water solution
Not maintaining the water temps at the right level causes the
soap not to dissolve in the water correctly
The soap would not get stirred up in the cleaning process if the
soap would be dissolved correctly in the first place
It would be too costly to change soap suppliers or add a filter to
the system – this option is the most cost effective
7. Identify, Select, and Implement The Solution
Force-Field AnalysisDriving Forces1.Improving the parts-washing operation would help the other operations within the company2. Reducing delays during this process would mean other operations would not see delays themselves3. Less time would be wasted waiting on parts to be washed4. There would be fewer customer complaints, because parts would now be able to be delivered on time5. The cleaning process might not be as troublesome6. Company saves money by not having to change soap suppliers or having to install a filter to the washer which actually might not solve anything
Restraining Forces1. Operators might resist the change in operating procedures2. Management might not want to spend the time to train operators on the new operating procedures3. Some management might believe it is better to throw money at the problem instead of changing procedures
Actions1. Implement a quality control program which rewards the operation with the fewest delays2. Make sure the parts washer operators understand that they will receive the training they will need3. Provide management with figures that show how installing a filter system or changing soap suppliers would basically be like throwing money out the window
Summary
Identified SolutionChanging Operating Procedures
Add more soap-and-water solution
Maintaining the Water Temperatures
This option is the most cost effective
Case Purpose • Slowed production at WP Inc. • A result of clogged spray nozzles in parts
washer • Leading to increased downtime
Possible Causes • Build-up of Soap
• Water• Too much soap • Operating procedures • Water tank • Cleaning
Potential Solutions • Installing a filter system to tank • Changing Operating Procedures • Change Cleaning Procedures • Change type of Soap Used
Reference:
Summers, D. (2010). Quality. Upper Saddle River, New
Jersey: Prentice Hall.