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WP Inc. case study

WP Inc. case study. Lisa M. Cochran MGMT580PA Quality Management & Statistical Analysis Southwestern College Dr. Michael Corriere 13 June 2012. CASE STUDY OVERVIEW. WP Inc. manufactures small metal parts Uses customer’s design

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WP Inc. case study

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

  2. CASE STUDY OVERVIEW • 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. PROBLEM-SOLVING STEPS & TOOLS Summers, 2010, p. 48, Fig 3.1

  4. PARTS WASHER OVERVIEW Summers, 2010, p. 48, Fig 3.1

  5. PROBLEM-SOLVING STEPS • 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. BRAINSTORMING • 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. PROBLEM STATEMENT RESULTS • The spray nozzles on the Automatic Parts Washer are frequently clogged because the nozzles are too small.

  8. INFORMATION GATHERED • 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. BRAINSTORMING REVISITED • 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. REVISED PROBLEM STATEMENT • 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. PROBLEM-SOLVING STEPS USED Summers, 2010, p. 48, Fig 3.1

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

  13. FORCE-FIELD ANALYSIS Driving forces 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 Review and plan to install filter in tank Design and build filter Install filter Increase water temperature Test Summers, 2010, p. 79

  14. MANAGEMENT SUMMARY • 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. REFERENCES • Summers, D. (2010). Quality/5e. Upper Saddle River, NJ: Prentice Hall.

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