Case Study 3.1: - PowerPoint Presentation

Slide1

Case Study 3.1:WP Inc.Problem-Solving

Group 2: Danny Taylor, Jason Thigpen, Susan Leuquire

MGMT 580 Quality Management & Statistical Analysis

Instructor: Ms. Connie Fleming

Southwestern College Professional StudiesSlide2

Problem StatementThe spray nozzles of the automatic parts washer frequently clog with particles causing the parts washer to be shut down. This is unacceptable and delays every process in WP Inc. because every part manufactured goes through the parts washer. Slide3

List of Possible Particle IdentitiesHard-water buildupCalcium

Chips from the parts

Paint chips

Soap flakes

Result of a chemical reaction

Gravel or

dirtCorrosion or rustSlide4

List of Potential CausesHeated water caused condensation and increased soap contentWritten process calls for adding soap/water solution when there is a decrease in the fluid level of the tank

During cleaning, soap particles become free floating

Parts washer has not been at the appropriate level for the soap to dissolve properly

No filtering system exists between

the tank and nozzlesSlide5

Cause & Effect Diagram

Nozzles

clogged

Heated water causing condensation

Written process to add soap

Free floating soap particles

Temperature

Level too low for soap to dissolve properly

No filtering system between tank & nozzlesSlide6

Cause & Effect AnalysisTo help mitigate the causes, these steps can be taken:

Changing the percentage of soap solution to ensure soap solution dissolves completely

Use a different brand of soap solution which does not need to be as hot to dissolve completely

Install an inline filter to the line running between the pump

motor and nozzles

Move the pump off of the bottom of the tank

Add a strainer to the suction line

Check the water heater capability for hot waterSlide7

Force Field AnalysisIssue: Parts Washer Spray Heads are Constantly Clogging

Driving Forces:

1. Water in the tank evaporates

leaving too much of the soap

solution behind; accumulation

of the soap solution could be

clogging the heads.

2. The temperature of the water

in the tank has not been sufficient

enough to properly dissolve the

soap solution; accumulation of the

soap solution could be clogging the heads.

3. The parts washer does not have filtration equipment installed between the tank, motor, and/or the spray heads.

Restraining Forces

1.This is the only parts washer now

approved by the EPA.

2.The parts washer is beginning to

slow the overall process which could

slow product time to customers.3.Adding additional parts to the washer to resolve the issue could cost several hundred dollars and/or void

the warranty.Slide8

Possible Actions to be taken1. Place an

inline filter

between the motor and the spray heads where it is accessible for cleaning and maintenance. 

2. 

Place the pump on a brick inside the tank

so it will not pull water/soap solution directly from the bottom of the tank and add a strainer to suction line; the tank bottom is where 95% of the particles will settle keeping the pump directly off the bottom of the tank and adding a

strainer

on the suctio

n line

will

keep most particles out of the heads.

3. Make

repairs to water heater

to keep constant temperature for best possible mixture/dilution of the soap solution.

4. Keep the lid of the parts washer closed during operation to lessen the evaporation caused by heating the water. 

5. Look into different soap solution that will better mix with the water and not require such a high temperature to lessen the water lost to evaporation.  Slide9

Follow Up Actions

Monitor the number of days/hours between the last time the nozzles clogged before raising the pump and installing a strainer on the suction line and compare it to the next time it happens. If the times are far apart, then the fix is working and delays will be cut down if not totally eliminated.

Monitoring will also be necessary with the addition of the inline filter. The filter will need to be checked in accordance with manufacturers specifications in regards to the amount of water/soap concentrate being passed though it daily. When the filter is serviced, the contents can be monitored to see exactly what, and how much, is being filtered out of the washer.

Lastly, the water heater can be verified for accuracy by keeping an eye on a thermostat. Workers using the washer can check the temperature before each use and record it in a log book. The log book can be reviewed by maintenance personnel each shift. If there is a variance in the temperature, the maintenance personnel can make adjustments to the heater to correct the problem.

All

corrective measures will be watched each shift for a 30-day period; if all is going according to plan, the next review will take place at the 60-day mark. After 60-days, if the nozzles are no longer clogging a normal maintenance schedule will begin in accordance with manufacturers specifications. If after 60-days there are still issues with the nozzles

clogging,

a new soap solution will be researched and a new plan for repair implemented. Slide10

SummaryThe purpose of this study is to address the issues WP Inc. is facing by clogged spray nozzles in their parts washer. This issue has slowed production in the company and corrections need to be done to reduce downtime in the parts washer, thereby increasing production.

3 possible corrective actions have been taken and a plan of further action has been set for follow up:

Placing the pump at a higher

level and install strainer

Installation

of inline filter

Monitoring/repairing

the water heater as needed

Results from lifting the pump and install the strainer will be tested as the first step. If insufficient improvement is shown, the filter will be installed and monitored at the beginning and ending of each wash process. Monitoring of the water heater will take place after the washer has been turned on with water and soap added, and before the parts are placed in the washer.

A time-line of 30 to 60 days has been set for this process.

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References

Summers

, D., 2010. Quality. (5

th

ed.) Upper Saddle River, NJ:

Pearson Education, Inc.

Filtrationsystems.com, 2003.

Ultrafit

Welded High Performance Liquid Filter Bags. Retrieved from

http://

www.filtrationsystems.com/filtermedia_ultrafit.htm