ISL334E Quality for Engineers

2018-2019 Fall Semester

Case 2

Group 19

70140216 - Bora Bilgin

70140235 - Çağıl Bedre
70140276 - İrem Yazıcı
70140317 - Doğancan Bulak
70160235 - Ozan Oğuz Erden
 Part 1

The problem solving group is made up of people who have nothing to do

with the parts washer. The operators and mainly the people who are involved in
the design or maintenance of the parts washer are preferred. The operator rather
than from the design or maintenance of it. The maintenance crew who service
the system come in handy. The designer gathers information from the operators
and the service technicians. The designers have a good idea of the problem by
looking into the design. The other people involved in the group are the process
engineers, plant manager, and volunteers helping with the problem.

Problem Statement: The parts washer regularly shuts down due to

blocked nozzles, causing severe time delays, which in turn prevents production.

Part 2

Brainstorming – Possible identities for the particles:

 Dirt from the machine.

 Small pieces of dirt cleaned from the parts.
 Large pieces of dirt left on the parts.
 Dust or debris from the machining or other operations.
 Soap build-up on the nozzle walls.

Revised Problem – Solving Statement: The parts washer shuts down

due to the build-up of particles in its nozzles which occur in the orifices
after half a day’s time.

Problem-Solving Steps:

1. Question all operators monitoring the process. Ask every detail of the
process.
2. Investigate the process in the morning and when the nozzles clog in the
afternoon.
3. Investigate the process in the evening and compare the information
throughout the span of time.
4. Find out what materials are being washed away in the system.
5. Investigate the ingredients of the soap and the hardness of the water used.
6. Compare the dirty water with clean water.
7. Use atomic absorption spectrometer to determine the particles running
through the system in its various stages.
 Part 3

Brainstorming – Soap build-up at the bottom of the tank:

 Operator training.
 Preventive maintenance.
 The Quality of the soap.
 Soap and water now mixed properly.
 Soap concentration.
 Dirty water.
 Water not so hot.
 The temperature of the water.
 Filter system.
 Drain system.
 The tank is not cleaned regularly.
 Dirt in air.
 Dirt in work area.

Cause and Effect Diagram:

 Force Field Analysis:

Driving Forces Restraining Forces

1. Stopped production from down
time.
2. Broken quality tools.
3. Parts are not clean.
4. Lots of time used to identify
the problem
5. Loss of money from stopping
production and troubleshooting
time.
1. Nozzles are clogging.
2. Wrong water temperature used.
3. Soap solution is not soluble in
the temperature of water used.
4. Soap build-up at the bottom of
the tank.
5. Free floating building up of
soap when new water is added.

Actions:

 Use new soap solution.

 Clean the bottom of the tank so that it does not build up at the bottom.
 Install a filtering system between the tank and the nozzles.
 Investigate the operators and periodically inspect the nozzles.

Brainstorming – Corrective actions:

 Clean the tank.

 Check the concentration of soap in the tank.
 Check the limits of soap when adding into the water.
 Prevent particle from entering into the nozzles.
 Use new nozzles.
 Keep soap agitated in the tank.
 Maintain a schedule for the service and maintenance of the tank.

The corrective actions are evaluated first. A plan of action is created from the
possible corrective actions.

1. Clean the rank neatly and thoroughly.

2. Place a lid over the top of the tank to slow evaporation.
3. Do not add more soap while replacing the water.
4. The particle filter is placed in between the tank and the nozzles.