1. WP Inc: spray nozzle blues
MGMT 580 FINAL PROJECT: S. BATCHELDER
WP Inc: spray nozzle blues

2. 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

3. 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

4. The Fishbone: Cause & Effect.
MACHINE PROBLEMS
WATER PROBLEMS
Water in tank not optimal temperature
No filter
system
Malfunction
Evaporation causes level
variation
Operator Error
CLOGGED
WATER
NOZZLE
Residue in tank
Soap/water
Mixture
Flakes
SOAP PROBLEMS

5. Mitigate the causes. Machine problems Operator training
Investigate adding filtration system
Audit of parts and performance

6. 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

7. Force Field Analysis 1. Operator Training DRIVING FORCES
RESTRAINING FORCES
Simple process adjustments
Motivation
Low cost
solution
Inconsistent
Higher
Morale
Time to implement

8. Force Field Analysis 1. Overhaul Machinery/ New Equipment
DRIVING FORCES
Overhaul
Machinery/
New
Equipment
RESTRAINING FORCES
Better technology (filter, temp control)
Expensive
Process better, more reliable
Compatibility
Spend money to save money
Learning curve

9. Force Field Analysis 1. Fill water/ New brand of cleaning solution
DRIVING FORCES
Fill water/
New brand of
cleaning
solution
RESTRAINING FORCES
Added steps to process
Could be
lower cost
Opportunity for new partnership
Availability
Additional cost to implement

10. 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

11. 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

12. Corrective Action Plan
ISSUE
SOLUTION
TIMEFRAME
SUCCESS
EVALUATION
PERSON
RESPONSIBLE
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
Above plus facilities.
No filtering system
Explore options to add system
After results of items 1 and 2 determined
Filtering system installed
Operations supervisor, purchasing,
controller

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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.

20. 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.

21. 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.

22. References
“Cause & Effect Diagram.” (2014). Retrieved from TC aspx
“Force Field Analysis.” (2014). Retrieved from
“Spray aqueous parts washers.” Retrieved from 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