1. Lisa M. Cochran MGMT580PA Quality Management & Statistical Analysis Southwestern College Dr. Michael Corriere 13 June 2012

2.  WP Inc. manufactures small metal parts  Uses customer’s design  Recurring problem w/ spray nozzles in parts washer that frequently clog  Causes parts washer to shut down  Causes serious time delays for everything  Parts washer is the only option Summers, 2010, p. 100

3. Summers, 2010, p. 48, Fig 3.1

5.  Plan:  Recognize a problem exists  Form a quality improvement team  Develop performance measures  Clearly define the problem  Document and analyze problem/process  Determine possible causes  Do:  Identify, select, and implement the solution  Study & Act:  Evaluate the solution  Ensure performance  Continuous improvement Summers, 2010, p. 49, Fig 3.2

6.  Plan:  Recognize a problem exists – spray nozzles clog frequently  Form a quality improvement team - me  Develop performance measures – how do I know I have made the correct change? The nozzles aren’t clogging anymore  Clearly define the problem – spray nozzles clog frequently, causing serious time delays for the entire manufacturing plant  Document and analyze problem/process – create a log  Determine possible causes – nozzles are too small, nozzles are developing soap scum build up-causing it to clog, pump isn’t strong enough Summers, 2010, p. 49, Fig 3.2

7.  The spray nozzles on the Automatic Parts Washer are frequently clogged because the nozzles are too small.

8.  Nozzles don’t spray as freely as they should  7 times – nozzles clogged completely  2 of these times – clogged midday  5 of these times – clogged at end of day  0 of these times – morning  Why clogging?  Small particles clogging orifices of nozzles  Restricts flow of soap & water solution  Causing nozzles to clog even further  Eventually shutting everything down  Small particles are white/flakelike when dry Summers, 2010, p. 101

9.  Plan:  Recognize a problem exists – spray nozzles clog frequently  Form a quality improvement team - me  Develop performance measures – how do I know I have made the correct change? The nozzles aren’t clogging anymore  Clearly define the problem – spray nozzles clog frequently, causing serious time delays for the entire manufacturing plant  Document and analyze problem/process – create a log  Determine possible causes – nozzles are too small causing the small particles to get stuck, causing the soap/water solution to clog it even more, causing the parts washer to shut down Summers, 2010, p. 49, Fig 3.2

10.  The spray nozzles on the Automatic Parts Washer are frequently clogged because the small particles to get lodged in the small orifices, which causes the soap/water solution to clog it even more, eventually causing the Automatic Parts Washer to shut down.

11. Summers, 2010, p. 48, Fig 3.1

12. NOZZLES WON’T CLOG NO FILTERING SYSTEM EVAPORATIONHIGH TEMPERATURE NEEDED CAUSES OF SOAP BUILDUP IN BOTTOM OF TANK TEMPERATURES IN TANK TOO LOW HOW SOAP DISSOLVES BEST UNNECESSARY INCREASE OF SOAP SOLUTION DISTURBED SOAP PARTICLES INCREASES SOAP CONCENTRATION FILTER NEEDED BEFORE NOZZLES FILTER NEEDED IN TANK NEEDED TO PROTECT NOZZLES Summers, 2010, p. 70

13. PLAN OF ACTION RESTRAINING FORCES  Reduce shut downs  Increase manufacturing numbers  Increase production  Prevent Future clogs  Must design filters  Must determine where filter will go  Must ensure water temp is warm enough DRIVING FORCES 1.Review and plan to install filter in tank 2.Design and build filter 3.Install filter 4.Increase water temperature 5.Test Summers, 2010, p. 79

14.  Do:  Identify, select, and implement the solution  Install filters for nozzles in the tank  Increase water temperature in the tank to dissolve soap  Study & Act:  Evaluate the solution  Because the temperature is warmer the soap dissolves  In case the water temperature gets too cool, filters are a back up in prevent clogging nozzles  Ensure performance  Run with warmer water and filter installed  Corrects the problem  Continuous improvement  Maintain and clean filters daily at the end of the day to ensure the filters don’t become a clogging problem  Regularly test the water temperature to ensure soap is dissolving Summers, 2010, p. 49, Fig 3.2

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