Lisa M. Cochran
MGMT580PA
Quality Management & Statistical Analysis
Southwestern College
Dr. Michael Corriere
13 June 2012
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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
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Causes serious time delays for everything
Parts washer is the only option
Summers, 2010, p. 100
Summers, 2010, p. 48, Fig 3.1
Summers, 2010, p. 48, Fig 3.1
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Plan:
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Do:
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Recognize a problem exists
Form a quality improvement team
Develop performance measures
Clearly define the problem
Document and analyze problem/process
Determine possible causes
Identify, select, and implement the solution
Study & Act:
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Evaluate the solution
Ensure performance
Continuous improvement
Summers, 2010, p. 49, Fig 3.2
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Plan:
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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
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The spray nozzles on the Automatic Parts
Washer are frequently clogged because the
nozzles are too small.
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Nozzles don’t spray as freely as they should
7 times – nozzles clogged completely
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2 of these times – clogged midday
5 of these times – clogged at end of day
0 of these times – morning
Why clogging?
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Small particles clogging orifices of nozzles
 Restricts flow of soap & water solution
 Causing nozzles to clog even further
 Eventually shutting everything down
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Small particles are white/flakelike when dry
Summers, 2010, p. 101
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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
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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.
Summers, 2010, p. 48, Fig 3.1
CAUSES OF SOAP BUILDUP IN BOTTOM OF TANK
EVAPORATION
INCREASES SOAP
CONCENTRATION
HIGH TEMPERATURE NEEDED
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
DRIVING FORCES
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RESTRAINING FORCES
Reduce shut downs
Increase manufacturing
numbers
Increase production
Prevent Future clogs
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Must design filters
Must determine where
filter will go
Must ensure water temp
is warm enough
PLAN OF ACTION
1.
2.
3.
4.
5.
Review and plan to install filter in tank
Design and build filter
Install filter
Increase water temperature
Test
Summers, 2010, p. 79
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Do:
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Identify, select, and implement the solution
 Install filters for nozzles in the tank
 Increase water temperature in the tank to dissolve soap
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Study & Act:
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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
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Ensure performance
 Run with warmer water and filter installed
 Corrects the problem
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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

Summers, D. (2010). Quality/5e. Upper Saddle River,
NJ: Prentice Hall.