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.