WP INC: SPRAY NOZZLE BLUES

MGMT 580 FINAL PROJECT: S. BATCHELDER

What’s the problem?

Spray nozzle on the parts washer is clogging Integral part of the manufacturing

process Each part manufactured goes through

washer Creates time delays Only alternative for cleaning parts to

maintain quality system

The causes could be… Nozzle installed

incorrectly Debris in water causing

clog From water in tank From water fed through

line Buildup from hard water Debris from parts Soap interaction Malfunction in nozzle Mineral deposit

The Fishbone: Cause & Effect.

CLOGGEDWATERNOZZLE

SOAP PROBLEMS

MACHINE PROBLEMS WATER PROBLEMS

Evaporation causes levelvariation

Water in tank not optimal temperature

Operator Error

Malfunction

No filtersystem

Residue in tankSoap/waterMixture

Flakes

Mitigate the causes.

Machine problems Operator training Investigate adding

filtration system Audit of parts and

performance

Mitigate the causes.

Soap and water problems Operator training Revise operational

processes Explore alternative brands

of cleaning solution Temperature control

system Supply fill water to counter

evaporation

Force Field Analysis 1.

OperatorTraining

DRIVING FORCES

Simple process adjustments

RESTRAINING FORCES

Low costsolution

HigherMorale

Motivation

Inconsistent

Time to implement

Force Field Analysis 1.

OverhaulMachinery/NewEquipment

DRIVING FORCESBetter

technology (filter, temp control)

RESTRAINING FORCES

Process better, more reliable

Spend money to save money

Expensive

Compatibility

Learning curve

Force Field Analysis 1.

Fill water/New brand ofcleaningsolution

DRIVING FORCES

Could belower cost

RESTRAINING FORCES

Opportunity for new partnership

Added steps to process

Availability

Additional cost to implement

Follow up the Force Field. The low cost option is to correct the

temperature control issue OR explore alternatives to cleaning

solution that may dissolve at lower temp

Both would involve an element of incorporating clean fill water to alleviate evaporation

Last resort is new equipment or modifying existing equipment for cost reasons

Corrective actions could be… Incorporate a fill water

system AND… Operator training

Maintain temperature Use water only to fill after

evaporation Investigate alternate

brand of cleaning solution or adding a filtration option for existing machine

Corrective Action PlanISSUE SOLUTION TIMEFRAME SUCCESS EVALUATIO

NPERSONRESPONSIBLE

Water temp. not optimal

Train ops to monitor and adjust as needed

2 weeks to reach all operators

Consistent results in temp samples

If success fixes problem, completed.

Ops Supervisors/Manager

Solution used to fill tank when evaporation occurs

Implement clean fill- water solution

After results of item 1 determined

Soap deposits reduced in tank

If success fixes problem, completed.

Above plus facilities.

No filtering system

Explore options to add system

After results of items 1 and 2 determined

Filtering system installed

If success fixes problem, completed.

Operations supervisor, purchasing,controller

Implementing the CAP… Each action is determined

by success or failure of previous action

Action 1 (training): Document what process is for

achieving and maintaining correct temp range and acceptable variations.

Establish training schedule for all operators to educate

Two weeks should cover all shifts/employees

Implementing the CAP… Action 2 (clean fill water)

Evaluation and testing of water supply to ensure no negative reaction with cleaning solution

Determine water delivery system and storage methods

Establish guidelines and process on when and how to use the clean fill water

Any additional process changes to include this step in washing parts

Implementing the CAP… Action 3 (install filter)

Determine if existing machine can be fitted with filter

If so, find cost, installation procedure and downtime expected for machine

Additional training, process steps may be needed

If unable to modify existing machine, explore purchasing new machine

Follow up. Action 1 (training):

Sample water temp regularly

Compare with instances of nozzle clogging before implementation of action

If action remedies problem, further analysis could be done to determine the exact temp at which the nozzle starts to experience clogging

Follow up. Action 2 (clean fill water):

Sample water in tank regularly to determine presence of particulate matter

Gather data to further evaluate effects of fill water temp and volume on cleaning solution

Evolve process for water storage and delivery as needed to increase efficiency in process

Follow up. Action 3 (install filter):

Determine best option for modifying or purchasing new equipment, contact manufacturer of machine

Evaluate efficiency and any changes in initial costs as well as total cost of ownership of this action after implementation

Conclusion

Action 1 is very low cost, low impact solution to try that has seems to have a high probability of working.

Temp affects both the functionality of the machine as well as the soap used in the solution.

The build up of non-dissolved soap is prime suspect

Training the operators and making small adjustments to operational process could be solution.

Conclusion

The fill water option is still lower cost, but involves a lot of testing for compatibility and best practices for introducing a new variable to the process.

This solution would also add to the operational process, but could easily be implemented with the proper instruction.

The next step up would be to modify the machine, or take it a step further and replace it.

Conclusion

Adding a filter could be expensive, so could replacing the machine. Additionally, the time lost and any additional training with new equipment could be taxing. In the long run, it could result in a more efficient process.

A quick search shows that the machine type described could retail for around $8,000. A considerable chunk of money, but not usually a back-breaker.

With a three-tiered action plan, there is no pressure to spend a lot of money right away, the first two options are the easier ones.

References “Cause & Effect Diagram.” (2014). Retrieved from

http://office.microsoft.com/en-us/templates/cause-and-effect-diagram-TC006082737.aspx

“Force Field Analysis.” (2014). Retrieved from http://www.mindtools.com/pages/article/newTED_06.htm

“Spray aqueous parts washers.” Retrieved from http://www.safety-kleen.com/products-services/parts-cleaning-technologies/aqueous-parts-washer/spray

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

“Writing an effective corrective action plan.” (2014). Northwestern University Research [online]. Retrieved from http://irb.northwestern.edu/policies/compliance/corrective-action-plan