Using DMAIC Six Sigma to systematically improve shopfloor production quality and costs

Purpose – This study sets out to highlight how a leading manufacturer of tooling, with its continuous improvement drive, has leveraged DMAIC Six Sigma potential to realize cost savings and improved quality on their shopfloor. The study examines one of the shopfloor chronic quality issues which deals with finding a way to reduce the amount of warp incurred in Amada A‐Station punches during the heat‐treat process. Design/methodology//approach – The goals of this specific study were achieved by utilizing Six Sigma tools such as “brainstorming, process mapping, fish‐bone diagrams, histograms, and control charts”. Findings – The analysis resulted in a number of findings and recommendations. A major contributor to the warp was the method used to fix the parts. It was found that, by using a new fixture to hang the parts, the amount of warp could be greatly reduced. The major recommendation was that the new heat‐treat fixture design be implemented as soon as a reliable fixture design has been proven. The value of implementing this new fixture design equates to roughly $10,000 per year in savings, which is due to the elimination of a secondary grinding operation and elimination of scrap parts. The company expects millions of dollars in annual savings as DMAIC Six Sigma process is rolled out to areas on the shopfloor. Originality/value – The case study shows DMAIC Six Sigma process is an effective and novel approach for the machining and fabrication industries to improve the quality of their processes and products and profitability through driving down manufacturing costs.