1. WP Inc. Case STUDY 3.1 Problem Solving Jonathan Stanley & Kari Eddings
Southwestern College Professional studies
Dr. Michael corriere

2. Background WP Inc. is a manufacturer of small metal parts.
Using customer designs they create tools, stamps, bends, and forms the metal parts; and deburrs, washes, and ships to customers
Multiple reoccurring problems with automatic parts washer
The spray nozzles frequently clogging particles
This causes time delays due to every part goes through the washer
Critical aspect in the cleaning process with no alternative because of EPA regulations.
There are a plethora of issues WP Inc. need to address with their manufacturing of metal parts. At the top of the list the automatic parts washer is the central hub that the whole process runs through. It cleans and scrubs all the dirt away like dishwashers do. The spray nozzles happen to cause problems cleaning the parts washer and cause this imperative system to shutdown. This causes ridiculously long delays in the quality process and must be resolved.

3. Problem Solving Statement/Steps
Need to figure out how to stop the clogging of the nozzles, resolve and fix the floating particles.
Establish a quality management improvement team
Establish performance standards and measures
Clearly state the problem
Once the problem is identified document and analyze the problem
Determine why, what are the issues, and the causes
Once all information is gathered develop plan of attack
Implement, revise, troubleshoot, and evaluate the solution
Always look to innovate and improve

4. Collective Brainstorming
In order to stops the clogging the spray nozzles need to be sprayed regularly. This will minimize the chance for floating particles to contaminate the clogged nozzles. This needs to be done with heated water so the particles do not settle at the bottom of the tank.
The quality management team will be Kari and JJ. Together we will establish conformity standards and measures to minimize problems and maximize performance.
The particles are severely slowing the process. It could be hard-water buildup, calcium, chips from the parts, paint chips, soap flakes, something by chemical reaction, or gravel dirt. The commonality is these can all be reduced/eliminated by keeping the nozzles clean, spraying frequently, and prevent time delays.
Then document the results, create a log book and track everything.
The nozzles are too big and too small at the same time. The soap scum keeps developing after two minutes.

5. Flowchart New soap and heated water are put in tank Water is emptied
YES NO
Is water
dirty?
Coils
heat
water NO
Dirty parts are placed in machine
Parts
are
run
Parts washer is turned on
Are parts clean?
Parts move to next step
YES
Evaporation occurs; water and soap are added

6. Cause & Effect Materials Methods Nozzle Clogs Up People Machines
Non-dissolvable soap
Lack of filter system between tank & nozzle
Evaporation should occur at correct temperature
Soap & water solution clogs nozzle
Residue build-up in the tank
When tank drains new solution is put in
Increasing soap concentration
Nozzle Clogs Up
Washer has issues mostly in the afternoon
Operator records daily problems
Tank temperature
is too low
More solution is added as fluids decrease
Operator needs
Proper training
No filtering system
Tank is not cleaned often enough
People
Machines

7. Washer Nozzle Clogging Up
Why - Why Diagram
Why do the nozzles not spray as they should?
Why is the temperature not warm enough?
Washer Nozzle Clogging Up
Why is the solution changed so often?
Why is washing parts critical to the process?
Why do washer tanks continue to break?

8. Resolution and Corrective Measures
Stopping the clogging in the washer nozzles
Resolve automatic parts washer
Remove dirt and soap scum using hot water
Reduce the delays in the washing operation
Quality management and establishing team
Resolve issues and customer service satisfaction

9. Brainstorming Results
In order to stops the clogging the spray nozzles need to be sprayed regularly. This will minimize the chance for floating particles to contaminate the clogged nozzles. Spraying every 12 hours.
The particles are severely slowing the process. The soap scum is the culprit. We made the nozzles larger in diameter, with smaller holes so less soap scum and particles develop and changed the cleaning solution more often.
A log was created and is noting every step along the way.
The soap scum was developing after two minutes and is now significantly better after our changes. We also added more water pressure to the pump to become more proficient.

10. New Model Process Flowchart
Remove water
Clean water is filtered in tank.
Nozzles replaced, tank is cleaned, soap scum is washed out.
YES
Add soap after soap scum is removed.
Check tank, search for cleanliness NO
Rinse and repeat process to verify it works NO
Wash accordingly
Verify all is good and process works
Nozzle diameter is increased with smaller holes
Turn parts washer on, replace parts
YES

11. Why - Why Diagram Results
Increased nozzle size for better washing capabilities
Cleared Washer Nozzle
Monitored soap intake for proper cleaning
Installed filtration system & pump
Corrected heating element for proper evaporation temperature
Residue build-up in tank has been cleared

12. Force-Field Analysis/Actions
Driving Forces
Increase nozzle size make more smaller holes, change parts, enhance washing operation
Resolving the issues above increases productivity, reduces delays, and less time wasted fixing the machines
Spray water and clean more often.
Improve water infiltration system, use different pump with more pressure.
Most importantly with no delays or issues with parts, no soap scum buildup this means happy customers, more money for the WP Inc. and provides a PERMANENT fix.
Restraining Forces
Take offline 20 minutes a day to clean and use different cleaner
Research costs for new pump, establish budget to resolve problem
Maximize resources, personnel, and supplies
Training employees, change in process, procedural change, and documenting accordingly

13. Conclusion
Increasing the size of the nozzle, making the holes smaller, cleaning out the soap scum regularly, utilizing the soap properly and generating enough pressure to be adequate enough to clean with the new soap should resolve all possible issues of the soap buildup.
Also using heated water could cause the particles not to settle at the bottom of the tank and enhanced operating procedures with scheduled cleaning shifts should assist too.
This would appear to be both cost effective and advantageous to become more proficient and operate at full capacity. The quality management team can then take over from there and monitor accordingly.

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