WP Inc.: Automatic Parts Washer Process Improvement Final Project Summer D. Leifer MGMT580 – Quality Management and Statistical Analysis March 25, 2013 Mr. Mohamed Elaoudiy Southwestern College Professional Studies

Introduction Plan Do Study Act Conclusion References WP Inc.: Automatic Parts Washer Process Improvement

 WP Inc. Problem Solving Group  Problem- Auto Parts Washer Clogging  Problem Solving Methodology- Dr. Deming’s “PDSA” Introduction

PlanDoStudyAct Dr. Deming’s PDSA Process Improvement Model

Recognize problem exists Form an improvement team Act Plan DoStudy Dr. Deming’s PDSA Process Phase One: Plan Steps One and Two

Develop performance measures Act Plan DoStudy Dr. Deming’s PDSA Process Phase One: Plan Step Three

Timing of Nozzle Clogs in One Month Period

Clogged Parts Washer Causes Affinity Diagram

Clearly defining the problem Act Plan DoStudy Dr. Deming’s PDSA Process Phase One: Plan Step Four

Problem Statement Status Quo Destabilizing Moment Consequences

Document and analyze the process and/or problem. Act Plan DoStudy Dr. Deming’s PDSA Process Phase One: Plan Step Five

Parts Washer Process Flowchart Parts Washer is turned on Dirty parts are placed in the machine Parts are run Are parts clean? Parts move to the next step Is wate r dirty? Water is emptied New soap and water are put in tank. Evaporation occurs; water and soap are added Coil heats water. YES NO

Clogged Nozzle Cause and Effect Diagram Parts Equipment issues Additives Operator Error Chips from the parts Paint chips from the parts Calcium build-up Soap flakes/build-up Chemical reaction Improper water temp Improper operations Insufficient maintenance Nozzle defects Parts Washer defects Old equipment Clogged spray nozzles Hard water Gravel or dirt Improper soap/water mixture

Determine possible causes Perform root cause analysis Determine root cause Act Plan DoStudy Dr. Deming’s PDSA Process Phase One: Plan Step Six

Soap Buildup on Tank Bottom Cause and Effect Diagram Water Temperature Equipment issues Free floating particles Dissolve best at elevated temp Low temps do not permit proper dissolution Soap concentration increased/cannot be held in solution Soap particles fall to bottom/disturbed during cleaning No filter system between tank and nozzles Soap buildup on the bottom of the tank Tank water heated/water evaporates Fluid level decreases/more soap & water added

Identify, Select and Implement the Solution Act Plan Do Study Dr. Deming’s PDSA Process Phase Two: Do Step Seven

Force-Field Analysis Driving Forces 1. Improving manufacturing and service quality assurance for all stakeholders 2. Delivering quality product on-time and per specification to customers leads to better customer relations 3. Improved parts washer process leads to less waste (e.g. time, money, resources) 4. Efficient processes lead to higher employee satisfaction Restraining Forces 1.Training operators on new processes 2.The costs of installing new equipment and revising training Actions 1.Change the parts washer operation process 2.Implement and provide training on revised process to current and new operators 3.Monitor the process change and adjust as necessary

Evaluate the solution Act Plan Do Study Dr. Deming’s PDSA Process Phase Three: Study Step Eight

Chart for Counts of Nonconformities (Clogs)

Ensure permanence Continuous Improvement Act Plan StudyDo Dr. Deming’s PDSA Process Phase Four: Act Steps Nine and Ten

 WP Inc. Problem Solving Group  Problem- Auto Parts Washer Clogging  Problem Solving Methodology- Dr. Deming’s “PDSA” Conclusion

Contact: Summer D. Leifer Questions?

Brassard, M., & Ritter, D. (1994). The memory jogger II (1st ed.). Salem, NH: GOAL/QPC. Summers, D. (2010). Quality (5th ed.). Upper Saddle River, NJ: Pearson Prentice Hall. References