Group 4 MGMT 580 Case Study 3.1 Shawndra Janne

Problem Statement The spray nozzles located in the parts washer are clogging, causing the parts washer to be shut down.

Observations  Nozzles perform well in the morning; issues are occurring later in the day after several uses  Particles are found to be clogging the small openings of the nozzles  The particles appear white and flaky when dry

Potential Reasons for Clogging  Are the nozzles defective?  Are the nozzles supposed to be serviced and/or replaced according to a specific timeline? If so, has that been happening on schedule?  Is the quality of the solution being used substandard?  Is the water being pumped at a fast enough speed to create the appropriate pressure to go through the nozzles?  Is the hose clogged, preventing the appropriate water pressure to go through the nozzles?

Possible Identity of Particles  Residual off of the parts that are being washed?  Un-dissolved cleaning solution?  Particle build-up that has formed on the inside of the hose and is being pushed through to the nozzle?  Hard water deposits?

Revised Problem Statement An unknown substance is forming in the nozzles, causing them to become clogged.

Cause and Effect The Water in the tank is heated Procedure Machine Why is there build up in the bottom of the water holding tank? Measurement Tank Environment No filtering system exists between the tank and nozzles Once water reaches a certain concentration level, the solution is compromised Soap dissolves best at an elevated temperature – temp has been too low More soap-and water solution is added when there’s a decrease in the fluid level Once solution is compromised, the soap precipitates to the bottom Film at bottom of tank is disturbed and particles become free-floating

Force Field Analysis How do we eliminate the soap build-up on the bottom of the tank?

Force Field Analysis Cont. (Pros)  Prevent parts washer from being shut down  Reduce time spent on unclogging sprayers  Eliminate the particles that are clogging the sprayers  Remain EPA compliant  Meet customer expectation  Reduce late orders  Increase number of future orders  Increase profits  Improve organizational processes

Force Field Analysis Cont. (Cons)  Cleaning process causes disturbance of soap particles at bottom of tank  Water is not being held at the appropriate temperature  There is no filtering system between the tank and the sprayer nozzles  Requires research to determine appropriate temperature  Requires redesign or purchase of existing parts washer to include a filtering system  Involves investment of time and money

Plan of Action  Establish the correct temperature that should be maintained in order to reduce the level of particle build-up at the bottom of the tank  Revise procedures to include regular monitoring of water temperature  Research the cost of implementing a filtering system into the existing parts washer  Implement regular training for the parts washer operators in order to establish sound practices and procedures in regards to refilling the tank, checking water temperature and making sure that the filtering process is running correctly

Summary WP Inc. have had some issues with their spray nozzles clogging up the washer. They have noticed that these problems occur after the nozzle has been used all day and it is at the end of the day when they begin to clog. The company put a few different research and observation theories in motion to help learn why the nozzles are being clogged. Having a team that brainstorms different causes will help the company in the long run.