Final Project – Case Study 3.1

1. Final Project – Case Study 3.1 Danielle Gooch MGMT580 – Quality Management & Statistical Analysis January 19, 2012 Dr. Michael Corriere Southwestern College Professional Studies

2. Part 1 Problem Statement

3. Problem Statement • Automatic parts washer’s nozzle clogging issue must be resolved to reduce time delays.

4. Part 2 Brainstorming List of Possible Identities for the Particles Revised Problem Statement Problem-Solving Steps to Discover Cause of Clogged Nozzles

5. Brainstorming List of Possible Identities for the Particles • Hard-water buildup • Calcium • Chips from the parts • Paint chips • Soap Flakes • Something caused by a chemical reaction • Some type of gravel or dirt

6. Revised Problem Statement • Must figure out what is causing white, flake-like particles to be trapped in nozzle orifices at the end of the day, to reduce time delays.

7. Problem-Solving Steps to Discover Cause of Clogged Nozzles Use the steps found in Dr. Deming’s Plan-Do-Study-Act (PDSA) cycle (Summers, 2010). • Plan • 1. Recognize a problem exists. • There has been a recurrent issue with the spray nozzles on the automatic parts washer. The nozzles are frequently clogging with particles causing for the machine to have to be shut down. This issue has been causing serious time delays (Summers, 2010). • 2. Form a quality improvement team. • For this project, a quality improvement team has been formed; Danielle Gooch.

8. Problem-Solving Steps to Discover Cause of Clogged Nozzles cont. • 3. Develop performance measures. • Service time • Number of sales • Number of incorrect procedures • Number of deviation from organizational policies • Profit • 4. Clearly define the problem. • The problem is clearly defined in the problem statement and the revised problem statement, also provided below. • Problem Statement: Automatic parts washer’s nozzle clogging issue must be resolved to reduce time delays. • Revised Problem Statement: Must figure out what is causing white, flake-like particles to be trapped in nozzle orifices at the end of the day, to reduce time delays.

9. Problem-Solving Steps to Discover Cause of Clogged Nozzles cont. • 5. Document and analyze problem/process. • The textbook provides a process map detailing the process of the washing of the parts. • 6. Determine possible causes. • It has been determined by the machine operator that the automatic parts washer’s spray nozzles are being clogged by a white, flake-like particle that is getting trapped in the nozzle’s orifices. Earlier, on slide 5, a brainstorming list was developed listing possibilities of what the particle substance may be. Also, a cause-and-effect diagram will be provided on slide 13 along with analysis of that diagram on slide 14.

10. Problem-Solving Steps to Discover Cause of Clogged Nozzles cont. • Do • 7. Identify, select, and implement the solution. • Here the solution will be identified and a plan of action will be developed (Summers, 2010). A force-field analysis will be provided on slide 15. Follow-up actions to the solution will also be detailed on slide 16.

11. Problem-Solving Steps to Discover Cause of Clogged Nozzles cont. • Study and Act • 8. Evaluate the solution. • For this step, an evaluation of the possible corrective actions will be provided on slide 17 as well as a plan of action for implementing the corrective actions on slide 18. • 9. Ensure the permanence. • For this step, a follow-up of the corrective actions will be provided on slide 19. This is to check to see if the corrective actions are working. • 10. Continuous improvement. • Slide 20 suggests any additional actions that should be taken to ensure that the problem stays resolved and the issue does not occur again.

12. Part 3 Cause-and-Effect Diagram Analysis of the Cause-and-Effect Diagram Force-Field Analysis Follow-up Actions Evaluation of Possible Corrective Actions Plan of Action to Implement Corrective Actions Follow-up on Corrective Actions Additional Actions that Should be Taken

13. Cause-and-Effect Diagram Temp too low, soap cannot dissolve No filter to catch particles Operator adds too much soap Buildup of Soap on Bottom of Tank Soap separates from solution Soap solution is too concentrated

14. Analysis of the Cause-and-Effect Diagram • Solution: The operator should spray out tank with water at the end of each day to remove the soap that may have collected at the bottom after emptying out the old soap solution. The operator should also ensure that the temperature of the water being used while cleaning the parts is hot enough to dissolve the soap in the solution. A filter should be installed in the tank to prevent particles being caught in the spray nozzles. The issue should be relatively easy to resolve and should not cost WP Inc. much, other than the cost to buy and install a filter.

15. Force-Field Analysis

16. Follow-up Actions that need to Happen • It has been determined that there are three parts to the solution to the issue with the soap buildup on the bottom of the tank, they are as follows; • A filter will be installed in the tank to ensure that no particles will get up to the spray nozzles. • During operation of the parts washer, the operator will ensure that the temperature of the water is hot enough to dissolve the soap. • Operator will spray out tank with hot water after the old solution has been drained out of the tank during the daily cleaning of the parts washer process.

17. Plan of Action to Implement Corrective Actions • Step One: Operator will completely clean out parts washer to include removing buildup of soap that has collected in the tank. • Step Two: The filter will be installed in the tank that prevents particles from going to spray nozzles. • Step Three: Parts washer will be filled with soap solution as normal and parts washer will be “test run” with hot water to ensure that the soap buildup is no longer an issue. • Step Four: During the normal cleaning process, operator will empty out old solution and spray out any soap that may have collected in the thank with hot water.

18. Evaluation of Possible Corrective Actions • Once the corrective actions have been implemented the parts washing process will be examined to ensure that the issue with the buildup of soap in the tank is no longer an issue. The parts washer will be run for a day or two and monitored to ensure that there are not any soap particles building up in the tank.

19. Follow-up on Corrective Actions • A week or two after the corrective actions have been implemented, the parts washing process will be re-evaluated and the tank will be inspected to ensure that there are not any soap particles built up in the bottom of the tank. If there are still issues with soap particle buildup, then additional corrective actions will be considered, such as using a different soap solution.

20. Additional Actions that Should be Taken • The quality improvement team at WP Inc. should also look into alternative corrective actions in the event that the corrective actions that have been determined fail to correct the issue with the buildup of soap in the parts washer tank. It was mentioned in the follow-up on corrective actions slide that one alternative solution would be to look into buying a different soap. The team could research other soap products and determine if the soap they are using is not the best choice for their business. They could also investigate the water temperature issue and determine if the error is an operator error or if the water heater is faulty.

21. Reference Summers, D. (2010). Quality. Upper Saddle River, NJ. Pearson.