WP Inc.

WP Inc. WP Inc. - Start

2016-07-09 30K 30 0 0

WP Inc. - Description

Case STUDY 3.1. Problem Solving. Jonathan Stanley & Kari Eddings. Southwestern College Professional studies. Dr. Michael corriere. Background. WP Inc. is a manufacturer of small metal parts.. Using customer designs they create tools, stamps, bends, and forms. ID: 397251 Download Presentation

Download Presentation

WP Inc.

Download Presentation - The PPT/PDF document "WP Inc." is the property of its rightful owner. Permission is granted to download and print the materials on this web site for personal, non-commercial use only, and to display it on your personal computer provided you do not modify the materials and that you retain all copyright notices contained in the materials. By downloading content from our website, you accept the terms of this agreement.

Presentations text content in WP Inc.


WP Inc.

Case STUDY 3.1Problem SolvingJonathan Stanley & Kari EddingsSouthwestern College Professional studiesDr. Michael corriere



WP Inc. is a manufacturer of small metal parts.

Using customer designs they create tools, stamps, bends, and forms

the metal parts; and deburrs, washes, and ships to customers

Multiple reoccurring problems with automatic parts washer

The spray nozzles frequently clogging particles

This causes time delays due to every part goes through the washer

Critical aspect in the cleaning process with no alternative because of EPA regulations.


Problem Solving Statement/Steps

Need to figure out how to stop the clogging of the nozzles, resolve and fix the floating


Establish a quality management improvement team

Establish performance standards and measures

Clearly state the problem

Once the problem is identified document and analyze the problem

Determine why, what are the issues, and the causes

Once all information is gathered develop plan of attack

Implement, revise, troubleshoot, and evaluate the solution

Always look to innovate and improve


Collective Brainstorming

In order to stops the clogging the spray nozzles need to be sprayed regularly. This will minimize the chance for floating particles to contaminate the clogged nozzles. This needs to be done with heated water so the particles do not settle at the bottom of the tank.

The quality management team will be Kari and JJ. Together we will establish conformity standards and measures to minimize problems and maximize performance.

The particles are severely slowing the process. It could be hard-water buildup, calcium, chips from the parts, paint chips, soap flakes, something by chemical reaction, or gravel dirt. The commonality is these can all be reduced/eliminated by keeping the nozzles clean, spraying frequently, and prevent time delays.

Then document the results, create a log book and track everything.

The nozzles are too big and too small at the same time. The soap scum keeps developing after two minutes.



Parts washer is turned on

Evaporation occurs; water and soap are added

Dirty parts are placed in machine

Parts are run

New soap and heated water are put in tank

Water is emptied

Parts move to next step

Is water


Are parts clean?









Cause & Effect



Nozzle Clogs Up



Soap & water solution clogs nozzle

Residue build-up in the tank

Increasing soap concentration

Evaporation should occur at correct temperature

When tank drains new solution is put in

Lack of filter system between tank & nozzle

Non-dissolvable soap

Operator records daily problems

More solution is added as fluids decrease

Operator needs

Proper training

Washer has issues mostly in the afternoon

Tank temperature

is too low

No filtering system

Tank is not cleaned often enough


Why - Why Diagram

Washer Nozzle Clogging Up

Why do washer tanks continue to break?

Why is washing parts critical to the process?

Why is the solution changed so often?

Why is the temperature not warm enough?

Why do the nozzles not spray as they should?


Resolution and Corrective Measures

Stopping the clogging in the washer nozzles

Resolve automatic parts washer

Remove dirt and soap scum using hot water

Reduce the delays in the washing operation

Quality management and establishing team

Resolve issues and customer service satisfaction


Brainstorming Results

In order to stops the clogging the spray nozzles need to be sprayed regularly. This will minimize the chance for floating particles to contaminate the clogged nozzles

. Spraying every 12 hours.


particles are severely slowing the process.

The soap scum is the culprit. We made the nozzles larger in diameter, with smaller holes so less soap scum and particles develop and changed the cleaning solution more often.

A log was created and is noting every step along the way.


soap scum


developing after two

minutes and is now significantly better after our changes. We also added more water pressure to the pump to become more proficient.


New Model Process Flowchart

Add soap after soap scum is removed.

Turn parts washer on, replace parts

Wash accordingly

Nozzle diameter is increased with smaller holes

Verify all is good and process works





Rinse and repeat process to verify it works

Check tank, search for cleanliness

Remove water


water is


in tank.






soap scum is

washed out.


Why - Why Diagram Results

Cleared Washer Nozzle

Increased nozzle size for better washing capabilities

Monitored soap intake for proper cleaning

Installed filtration system & pump

Corrected heating element for proper evaporation temperature

Residue build-up in tank has been cleared


Force-Field Analysis/Actions

Driving Forces

Increase nozzle size make more smaller holes, change parts, enhance

washing operation

Resolving the issues above increases productivity, reduces delays, and less time wasted fixing the machines

Spray water and clean more often.

Improve water infiltration system, use different pump with more pressure.

Most importantly with no delays or issues with parts, no soap scum buildup this means happy customers, more money for the WP Inc. and provides a PERMANENT fix.

Restraining Forces


offline 20 minutes a day to clean and use different cleaner

Research costs for new pump, establish budget to resolve problem

Maximize resources, personnel, and supplies

Training employees, change in process, procedural change, and documenting accordingly



Increasing the size of the nozzle, making the holes smaller, cleaning out the soap scum regularly, utilizing the soap properly and generating enough pressure to be adequate enough to clean with the new soap should resolve all possible issues of the soap buildup.

Also using heated water could cause the particles not to settle at the bottom of the tank and enhanced operating procedures with scheduled cleaning shifts should assist too.

This would appear to be both cost effective and advantageous to become more proficient and operate at full capacity. The quality management team can then take over from there and monitor accordingly.



Summers, D. (2010). 


. Upper Saddle River, NJ: Prentice Hall.






About DocSlides
DocSlides allows users to easily upload and share presentations, PDF documents, and images.Share your documents with the world , watch,share and upload any time you want. How can you benefit from using DocSlides? DocSlides consists documents from individuals and organizations on topics ranging from technology and business to travel, health, and education. Find and search for what interests you, and learn from people and more. You can also download DocSlides to read or reference later.