lisa m. cochran mgmt580pa quality management & statistical analysis southwestern college dr....
TRANSCRIPT
WP INC. CASE STUDYLisa M. Cochran
MGMT580PAQuality Management & Statistical Analysis
Southwestern CollegeDr. Michael Corriere
13 June 2012
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
PROBLEM-SOLVING STEPS & TOOLS
Summers, 2010, p. 48, Fig 3.1
PARTS WASHER OVERVIEW
Summers, 2010, p. 48, Fig 3.1
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
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
PROBLEM STATEMENT RESULTS
The spray nozzles on the Automatic Parts Washer are frequently clogged because the nozzles are too small.
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
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
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.
PROBLEM-SOLVING STEPS USED
Summers, 2010, p. 48, Fig 3.1
NOZZLES WON’T CLOG
NO FILTERING SYSTEM
EVAPORATION HIGH 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
CAUSE & EFFECT DIAGRAM
Summers, 2010, p. 70
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
FORCE-FIELD ANALYSIS
DRIVING FORCES
1. Review and plan to install filter in tank2. Design and build filter3. Install filter4. Increase water temperature5. Test
Summers, 2010, p. 79
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
REFERENCES
Summers, D. (2010). Quality/5e. Upper Saddle River, NJ: Prentice Hall.