1. Continuous Improvements
DMAIC Project
Victoria A Blackmer
MFGO619-Six Sigma for Manufacturing
Spring 2015

2. Define:
 SIPOC
 Stakeholder Analysis
 Performance Measures
 Preliminary Problem Statement

3. Process Name: Leco Cut-Off
Wheel Usage
Process Owner: Victoria TL of
QAM
Suppliers Inputs Process Outputs Customers
(Providers of the required
resources)
(Resources required by
the process)
(Top level description of the activity) (Deliverables from the
process)
(Stakeholders who place the requirements on the outputs)
Requirements Requirements
Purchasing Wheel Size
Composition
Quality
12” Material
Description:
CUTOFF12x085X1-
1/4 RESIN/RBBR
810-311-10
Wheel Life and
how much
12”-8”
Number of pieces
(parts) cut/Wheel
Quality Auditors
(QAM)
Quality Auditors
(QAM)
Wheel
Life/12” Leco
Blades
Blade worn
down from
12” 8”
Wheel
Cost/Inches used
Throw away worn
down blades
$12.51/blade
10 blades /box =
$125.10
Purchasing
Leco Saw Cut—Off
Machine
RPM &
Coolant
Vertical
Loading
Undefined Worn down 12”
Blade
8” 5”
Deac Leco
Machines & Lab
Personal
Input boundary
(When the
process starts)
Buying Leco
Cut-off 12”
Blades
Process name
Use 12” Cut-off
Wheels till worn
down
Output
boundary
(When the
process ends)
Dispose of cut-
off wheels after
Worn down
Process name
Change worn
blade
Replace with new
12” blade

4. Stakeholder Analysis Chart
Stakeholder
Important to
Project
Success
What do they want
Barriers to
Change?
Enablers to Change Gaining Commitment
Bought
into
Change
Purchasing High Minimum tool (Blade) Cost None None None Positive
Management Medium
To know what their employees are
doing outside of their normal work.
Misconception that
new task will
interfere with
operators
performance of std
Work.
Communicate to all
management via email
about their dept.
corporation to the process
and explain the intended
purpose.
None Neutral
Quality Auditors
(QAM)
High
To find a way to maximize blade
usage and cost for 12” blades
Each (QAM) keeping
up with data
collection, logging
blade replacement,
etc.
Clear Roles and
Responsibilities
Make sure the QAM team is
following Directives;
Collaboration Positive
Deac Department
Operators
Medium
Understand and be able to manage
new processes, Know how job is
going to be effected.
Understanding &
operators following
the process
directions
(Using labeled
containers correctly
and keeping up with
Saw Replacement
Log)
Training, making sure
operators are on the same
page and following new
performance measures
Directives
Explanation of
project/collaboration
Label different totes to
ensure correct requirements
are followed.
Neutral
Lab Personal Medium
Good wheels that work with their Leco
Cut-off Machine. Make sure that
changes are safe and wheels are able
to be used on a different machine
(Blade size).
Understanding &
Following the
process directions
(Using labeled
containers correctly
and keeping up with
Saw Replacement
Log)
None
Directives
Explanation of
project/collaboration
Label different totes to
ensure correct requirements
are followed.
Neutral

5. Performance Measures
 Instead of throwing away the
most costly item in the QAM
area (losing $1310.40 on 150
12” blades); It would make
sense to get as much usage out
of each blade to increase your
money’s worth.
 Fig 2 Illustrates size
comparison; which for this
project only the two worn
down dimensions (end sizes)
for 12” blades will be
measured from QAM Leco
Machine and DEAC Leco
Machine.
 Fig 2 shows that by not
throwing away the worn 12”
blade = it can still be used on
a different machine. This
example shows a savings of
3.12in that would have been
lost.
Fig 1 Shows the 10” blade used in
DEAC (Top Left), The Worn Down
12” Blade from QAM (Top Right),
and the end result of the 12” worn
down blade used on the cut-off
machine in DEAC (Bottom).
Fig 1
Fig 2

6. Preliminary Problem Statement
Between Feb. 2014-Feb. 2015 (150) 12” Blades were purchased and used until
they wore down passed the admitted track tolerance of the cut-off machine;
therefore, the blade had to be thrown away. Average inches per blade used were
3 ½ inches (540 inches used total). Average inches not used was 8 ½ inches
(1,260 inches total lost). Using the current data as an average last year a total of
$1310.40 was lost by throwing away worn down 12” blades. Instead of throwing
away the most costly item in the QAM area ; it would be beneficial to the company
if we could look into other possibilities of saving cost on maximizing the blade
usage.

7. Measure:
 Process Map/Value Stream Map
 Identification of Process Defects
 Measurement Plan
 Defect Ranking
 Final Problem Statement

8. Process Map
Buying
Leco Cut-
off 12”
Blades Remove the
nut, flange
and cut-off
wheel
Put on New
Cut-off
Wheel
Replace the
Flange, and
tighten the nut.
(caution not to
tighten the nut
too much)
When cutting part
make sure the coolant
is running, so the parts
don’t burn and the
wheel doesn’t break
Dispose of
cut-off
wheels
after Worn
down
Use 12” Cut-off
Wheels till worn
down
Remove the nut,
flange and worn
down cut-off
wheel
Change worn
blade
Replace with
new 12” blade

9. Identification of Process Defects
 Putting Parts in the Vise and the Vises are not clamped completely.
 Changing the Wheel: When replacing the blade the operator might not mount
it correctly: over tightening the nut, blade not in place, etc.
 Other things that could cause a wheel to be thrown away too soon or like last
year every worn down blade was thrown away.
 Parts not being secured down or oriented how they should be which can cause
the part to move and break the blade.
 The Leco Cut-off Machine could be overdue for maintenance PM
 Could have defective/worn vices or defective parts

10. Measurement Plan
 What is to be Measured:
 Once 12” blade is no longer useable (Worn Down) I will measure the blade & keep a
log of all worn down measurements.
 Next I will bring the 12” worn down blades out to a different department (DEAC)
where they have the same Leco Saw Cut-off machine except it uses 10” blades.
 DEAC will only be using my 12” worn down blades (from March 2015- on going).
Once they wear down the blade I will collect them, measure the remaining size of
the blade and log all measurements.
 How Often:
 Depends on how long it takes the wheel to wear down (till it is unable to cut parts
anymore).
 Check locations everyday
 Precision:
 Measuring both worn down blades from the two different machines, logging them
and calculating the cost savings by how many more inches are saved on the worn
down 12” blades by saving them for further use instead of throwing them away,
exact cost savings per inch used, and hopefully will prove that we can eliminate 10”
blade purchases all together.
 How Long:
 On going project to develop enough data to prove 10” blades are no longer needed.
 I gathered all my data, notes, evidence and turned in the Quality Network
Suggestion Plan Form.

11. Final Problem Statement
 Between Feb. 2014-Feb. 2015: (150) 12” Blades were purchased and used
until they wore down passed the admitted track tolerance of the cut-off machine
and then had to be thrown away. Average inches per blade used were 3 ½
inches (540 inches used total). Average inches not used was 8 ½ inches
(1,260 inches total lost). Using the current data as an average last year a total
of $1310.40 was lost by throwing away worn down 12” blades. Instead of
throwing away the most costly item in the QAM area ; it would be beneficial to
the company if we could look into other possibilities of saving cost on
maximizing the blade usage.
 With all the other cut-off saw machines in the plant it would be useful to
evaluate whether the worn down 12” blades could potentially be used on
different machines. If we can get more use out of the 12” worn down blades it
will potentially save money by getting more money per inch off the 12” blade;
furthermore, potentially reduce cost of purchasing a smaller blade size.

12. Analyze:
 Root Cause Validation

13. Root Cause Validation
10” Leco Saw Blades
Amount Cost
Pc Price $13.23
Box of 10 $132.30
Total Cost $793.80
The Next two pages provide evidence of
validation with the data I have been collecting
 The 12” blades in the QAM area wear down a lot
faster due to more use of the cut-off machine.
The 12” blades wear down faster than the other
10” machines.
 This means that there is no need to purchase
anymore 10” blades.
 The 10” blades even cost more to purchase than
the 12” blades. Charts on the right show the
actual cost.
 I kept the sample size the same (30 blades)
Documented for this project. Still an on going
process getting other areas who have the ability
to use the worn 12in blades instead of buying
bran new 10in blades that cost more for the
same amount of blades in a box.
12” Leco Saw Blades
Amount Cost
Pc Price $12.51
Box of 10 $125.10

14. Leco Saw Cut Off Machine (12in blades & 10in Blades)
# of 12in Blades Checked
12in Worn Down
Dimensions
# of dept. 909 Blades
Checked
Dept. DEAC Worn Down
Dimensions
1 8.25 1 5.25
2 8.00 2 6.25
3 8.00 3 7.25
4 7.50 4 5.75
5 8.00 5 5.75
6 7.75 6 5.13
7 8.00 7 5.50
8 8.25 8 5.25
9 8.50 9 6.25
10 8.50 10 5.50
11 9.00 11 6.25
12 8.50 12 5.50
13 8.50 13 6.25
14 8.50 14 5.50
15 9.00 15 5.75
16 9.00 16 5.25
17 8.50 17 5.25
18 9.25 18 5.75
19 8.75 19 6.50
20 8.00 20 6.50
21 8.75 21 6.00
22 8.75 22 5.25
23 8.00 23 5.25
24 8.00 24 6.00
25 8.75 25 6.25
26 7.75 26 5.75
27 8.75 27 5.50
28 8.50 28 5.50
29 8.00 29 6.00
30 9.00 30 5.75
Average Left-> Worn
Down Blade Dimensions
8.40 5.79
8.40in-5.79in = 2.61in
2.61 x 1.04 = $2.72 saved per blade
This table shows
(with a sample size
of 30 blades) that
after the 12in
blade is worn down
and not able to be
used on the 12in
Cut Off Saw it can
still be used on the
10in Cut off Saw.
Instead of throwing
away the 12in worn
down blade the
other Cut off
machines can get
an Average of
2.61in more usage
of the blade saving
$2.72.

15. # of Blades
12in Worn Down
Dimensions
How many inches used
from 12in blade
How much $ PER inch is being Used
How much $ is Lost by
Throwing Away
Formulas->
12-worn down
dimensions=inches used
$1.04*inches used= $ per in used
$1.04 *Worn Down
Dimensions= $ Lost
1 8.25 3.75 $ 3.90 $8.58
2 8.00 4 $ 4.16 $8.32
3 8.00 4 $ 4.16 $8.32
4 7.50 4.5 $ 4.68 $7.80
5 8.00 4 $ 4.16 $8.32
6 7.75 4.25 $ 4.42 $8.06
7 8.00 4 $ 4.16 $8.00
8 8.25 3.75 $ 3.90 $8.58
9 8.50 3.5 $ 3.64 $8.84
10 8.50 3.5 $ 3.64 $8.84
11 9.00 3 $ 3.12 $9.39
12 8.50 3.5 $ 3.64 $8.84
13 8.50 3.5 $ 3.64 $8.84
14 8.50 3.5 $ 3.64 $8.84
15 9.00 3 $ 3.12 $9.39
16 9.00 3 $ 3.12 $9.39
17 8.50 3.5 $ 3.64 $8.84
18 9.25 2.75 $ 2.86 $9.62
19 8.75 3.25 $ 3.38 $9.10
20 8.00 4 $ 4.16 $8.32
21 8.75 3.25 $ 3.38 $9.10
22 8.75 3.25 $ 3.38 $9.10
23 8.00 4 $ 4.16 $8.32
24 8.00 4 $ 4.16 $8.32
25 8.75 3.25 $ 3.38 $9.10
26 7.75 4.25 $ 4.42 $8.06
27 8.75 3.25 $ 3.38 $9.10
28 8.50 3.5 $ 3.64 $8.84
29 8.00 4 $ 4.16 $8.32
30 9.00 3 $ 3.12 $9.39
Total of 30 blades = 252.00 108 $ 112.32 $261.88
AVG/blade= 8.40 3.6 $ 3.74 $8.73
Waste Lost = 252 in 360in - 108 = 252 in lost $375.30-$112.32 = $262.98
252in x$1.04 = $261.88
Lost
Feb 2014-Feb 2015 (150 blades used)
(Using AVG)
150(Blades) x 8.40in =
1260 inches lost
150(Blades) x 3.6 = 540
inches used
540 x $1.04 = $561.60 Used
1260 x $1.04 = $1310.40
Lost
This Chart shows my calculations for a sample
size of 30 12in blades and exactly how much
waste is lost by throwing away the worn 12in
blade:
 The measurements of the worn down blade
 How many inches are being used
 How much money per inch is being utilized
 How much money per inch is being thrown
away
Calculations For 12in Blades Off
Dept. 715 QAM Leco Saw Cut-Off
Machine

16. Improve:
 Solution Selection Matrix
 FMEA
 Pilot Measurement Plan

17. Change
Blade at
~8.40”
Save Blade
Save Blade
Change
Blade at
~8.40”
Worn
Down
Track
Tolerance
COST/Usage
of 12” Blade
Wasted
Problem Root
Causes
Solutions
(What)
Specific
Tasks
(How)
Use tools to
remove
and replace
with new
bladeGive to
DEAC to use
Find another
Machine
Give to DEAC
to use
X X =
SCALE: 1-None 2-Somewhat 3-Moderate 4-Very 5-Extreme
Use tools to
remove
and replace with
new blade
4
4
4
5
5
3 60 No
5
5
4
3
5
5
5
5
5
12
5
12
5
60
80 No
No
Yes
Yes

18. FMEA (For Both Dept. QAM & DEAC)FAILURE MODE AND EFFECTS ANALYSIS 6/15/2015
Leco Cut-off Saw Machine: Reduce Waste Concentrating on 12" Blades Victoria Blackmer QAM Team Leader/Project
Item or
Process Step
Potential Failure
Mode
Potential Effect(s) of
Failure
Severity Potential Cause(s) Occurrence Current Controls Detection RPN
Clamp Part in
Vise
Vise not clamped
completely
Wheel breaks or Chips 3 Worn Cam, Vise Worn 1 Scheduled Maintenance 2 6
Clamp Part in
Vise
Vise not clamped
completely
The part flies out of the
clamps, the part spins in
the clamp, the part is not
cut correctly or most
likely cause the wheel
can chip or break
2
Part not clamped tight enough,
so it will move while cutting it.
2
Job instructions, Standard
work, Operator needs to
determine whether the vise is
worn or that they need to
make sure the part is correctly
clamped down.
1 4
Cut Part
Don’t cut through
the part completely
You can't analyze the
part and will need to cut
another part.
2 Worn Down Blade 4
Change out the wheel when
the blade is worn down to ~
8.40"
2 16
Cut Part
Don’t cut through
the part completely
You can't analyze the
part and will need to cut
another part.
2
Track Tolerance can not be
adjusted to increase usage of
blade
4
Replace worn down blades
with new blades because track
can not be moved and move
blade to Dept. DEAC
2 16
Wheel
Change
Not mounted
correctly on Spindle
Wheel Breaks or Chips 3 Operator Error 1
Job Instructions on how to
change the wheel correctly
1 3

19. Pilot Measurement Plan
 In order for this project to work, it requires
organization and clear communication with
my stakeholders:
 I provided Labeled totes in the QAM area
(Fig 1)
 I provided Labeled Totes and extra
instructions in DEAC and Lab areas for
reference reminders. (Fig 2).
Fig 1
Fig 2

20. Pilot Measurement Plan
 Once the 12-inch worn down blade
can no longer cut parts from Dept
(QAM) :
 I will Measure the 12-inch cut-off
Worn Down Blades (Fig 3)
 Log every 12-inch Worn Down
Blade (Fig4)
 Then place in the appropriate
labeled tote. (Fig 1)
Fig 3
Fig 4

21. Pilot Measurement Plan
 Send the 12-inch worn down blades
to Dept. (DEAC) and Lab area
where there is a Leco Machine that
uses 10-inch blades. (Fig 5)
 DEAC employees and Lad personnel
will use the worn down blades
instead of purchasing 10-inch
blades.
Fig 5

22. Pilot Measurement Plan
 All three shifts in DEAC and Lab
personnel are aware of this pilot
and all have been cooperating with
instructions.
 Once blade is worn down (from
DEAC & Lab) I will measure the
blade and log remaining size.
 Timeframe is on going.
 No issues so far have been
reported.

23. Control:
 PCP/PMCS
 Standard Work

24. Process Control Plan (PCP)
DEPT.
PROCESS NAME/
OPERATION
DESCRIPTION
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.
CHARACTERISTICS
CTQ?
METHODS
REACTION
PLANNO. PRODUCT PROCESS
PRODUCT/PROCESS EVALUATION/ SAMPLE
CONTROL
METHODSPECIFICATION/ MEASUREMENT
SIZE FREQ.
TOLERANCE TECHNIQUE
QAM Wheel Change LECO CM-20 n/a
12" Cut-off
Blade
N
Change Blade
Between
7 1/2" - 8 3/4"
Measure across
the blade with a
tape measurer.
1
When
blade is
worn
down
Blade
Dimension
Log Sheet
Notify Team
Leader or Group
Leader
QAM Cut Part LECO CM-20 n/a
Parts
placed
properly in
fixture
N
Parts oriented
correctly according
to part specifications
(located in
standardized work)
Part is
successfully cut
all the way
through in the
location
specified
1
Part
running
needs to
be
checked
every two
hours
Document on
Inspection
Chart
If a part fails:
contain parts,
notify group
leader and
quality engineer
QAM
Clamp Part in
Vise
LECO CM-20 n/a
Clamp
Pressure on
(on the
vice)
N
Parts need to be
securely and
correctly clamped
down in fixture.
Part not
clamped tight
enough, so part
will move while
cutting. Also,
an issue if wheel
blade breaks or
chips
1
Part
running
needs to
be
checked
every two
hours
Document on
Inspection
Chart
If a part fails:
contain parts,
notify group
leader and
quality engineer
DEAC Wheel Change LECO CM-15 n/a
Use Worn
Down
Blades
from DEPT
QAM
N
Use the Worn Down
Blades Provided until
they are worn down
off the DEAC
Machine.
Average is
Don't need to
measure. Just
place the worn
down blade in
the tote for QAM
to pick up
1
When
blade is
worn
down
Use labeled
totes
provided
Notify Team
Leader for Dept
QAM or Group
Leader

25. Prepared By: Victoria Blackmer
Department: QAM/DEAC/Lab
No. Step Description Helpful Information Illustrations
1 Turn off power
Prevents the motor from
running during the wheel
change.
2 Raise Wheel Guard Moves it out of the way.
3 Loosen Nut with tools
Use round bar and long
handled wrench to loosen the
nut.
4
Remove Nut, Flange and
Wheel
Remove the nut by hand.
Rotate counter-clockwise.
Remove the flange. Remove
the Wheel.
5 Replace Wheel on spindle
Make sure the wheel hole is
on the larger diameter
section of the spindle.
Reaction Plan: If any discrepancies are discovered or if you have further questions contact Qam team Leader
Standard Operating Work Procedure
Operating Procedure: Wheel Change
Equipment Description: LECO CM-20 & CM-15 Cut-off
1 2 3
4

26. Prepared By: Victoria Blackmer
Department: QAM/DEAC/Lab
No. Step Description Helpful Information Illustrations
6 Replace the Flange
Place the flange on the
spindle. Verify that it is
touching the wheel.
7 Replace and Tighten the Nut
Use wrench to tighten, but
DO NOT overtighten! The nut
will continue to tighten as the
mahcine is used and becomes
difficult to remove.
8 Lower the Wheel Guard
The guard protects the
operator from injury
9 Turn on Power
Move disconnect switch to
the up position to restore
power to the machine
Reaction Plan: If any discrepancies are discovered or if you have further questions contact Qam team Leader
Standard Operating Work Procedure
Operating Procedure: Wheel Change
Equipment Description: LECO CM-20 & CM-15
6 7
8

27. Prepared By: Victoria Blackmer
Department: QAM/DEAC/Lab
No. Step Description Helpful Information Illustrations
10
After every wheel change
each area (QAM/Deac/Lab)
are provided with labeled
totes.
QAM replaces the blade with
a new 12-inch blade. Deac &
Lab replaces the blade with a
worn down 12-inch blade
provided in the tote labeled
machine.
11
QAM area totes labeled with
instructions of where to put
the 12-inch blade
12
Worn down 12-inch blades go
into the middle tote.
Need to still be measured
13
Once it is measured and
documented it is placed in the
tote to the right.
Now the blades are ready to
be transported to the Deac &
Lab Dept. totes.
Reaction Plan: If any discrepancies are discovered or if you have further questions contact Qam team Leader
Standard Operating Work Procedure
Operating Procedure: Wheel Change
Equipment Description: LECO CM-20 & CM-15
11
12 13
13 13

28. Prepared By: Victoria Blackmer
Department: QAM/DEAC/Lab
No. Step Description Helpful Information Illustrations
14
Deac and Lab have totes labeled
next to the Cut-off machine with
instructions to use the 12-inch
blade first after each wheel
change.
There are no more 10-inch new blades
used at the cut-off machine in Deac &
Lab.
15
Deac & Lab replaces the blade
with a worn down 12-inch
blade.
16
Once the blade is worn down
past cut-off machine track
tolerance it is placed in the worn
down labeled gray tote.
There is also a sheet located next to
the machine to keep track of brakes,
and how often the blades are being
replaced.
17
Every week the QAM TL goes
around and collects the blades
out of the gray tote.
18
QAM TL then measures &
Documents the end size of
blade.
Log the measurements on the same
sheet used to log the "before" 12-inch
worn blade size.
Reaction Plan: If any discrepancies are discovered or if you have further questions contact Qam team Leader
Standard Operating Work Procedure
Operating Procedure: Wheel Change
Equipment Description: LECO CM-20 & CM-15
14
16
15

29. Why this Project Relates to
Continuous Improvement
 The elimination of waste increases effectiveness and efficiency to achieve
customer enthusiasm.
 Waste identification & elimination is the Global Manufacturing System.
 Waste is the central focus of continuous improvement.
 Once the current state is stabilized, we continuously improve to eliminate
waste, add value & standardized.
 Instead of throwing away worn down blades (waste); this CI project shows there
is an alternative way to just throwing away a material (money) that can actually
still be used.
 If we can get more use out of the 12” worn down blades it will potentially save
money by getting more money per inch off the 12” blade; furthermore,
potentially reduce cost of purchasing a smaller blade size.
 Next is to standardize this CI and implement it.