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Victoria Blackmer
Victoria Blackmer

1) The document describes a DMAIC project to improve the process of using Leco cutoff wheels at a manufacturing facility. 2) Currently, 12-inch cutoff wheels are used until worn down and then thrown away, resulting in $1,310 wasted per year. 3) The project aims to validate whether worn down 12-inch wheels can still be used on machines that normally use 10-inch wheels, saving additional usage and money. Data has been collected tracking wheel wear to analyze the potential cost savings.

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Continuous Improvements DMAIC Project Victoria A Blackmer MFGO619-Six Sigma for Manufacturing Spring 2015
Define: SIPOC Stakeholder Analysis Performance Measures Preliminary Problem Statement
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 CutOff 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
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
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 moneys 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
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 遜 inches (540 inches used total). Average inches not used was 8 遜 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.
Measure: Process Map/Value Stream Map Identification of Process Defects Measurement Plan Defect Ranking Final Problem Statement
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 dont burn and the wheel doesnt 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
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
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.
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 遜 inches (540 inches used total). Average inches not used was 8 遜 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.
Analyze: Root Cause Validation
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
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.
# 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
Improve: Solution Selection Matrix FMEA Pilot Measurement Plan
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
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 Dont 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 Dont 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
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
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
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
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.
Control: PCP/PMCS Standard Work
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
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
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
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
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
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.

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Presentation

  • 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 CutOff 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 moneys 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 遜 inches (540 inches used total). Average inches not used was 8 遜 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 dont burn and the wheel doesnt 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 遜 inches (540 inches used total). Average inches not used was 8 遜 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 Dont 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 Dont 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.
  • 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.