Crusher-Compatible Fragmentation: A DMAIC-Based Approach to Blast Optimization

This study presents a DMAIC-based approach to optimize blasting performance and achieve crusher-compatible fragmentation at the Walker-Severn Quarry in Ontario, Canada. By applying the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) framework, the study aims to enhance the integration between blasting and primary crushing operations. Several representative blasts will be simulated and evaluated using both aerial and terrestrial image analysis technologies to assess fragmentation characteristics. The investigation was guided by quarry-specific Key Performance Indicators (KPIs), ensuring that blast design modifications were both practical and operationally relevant. Through structured analysis and data-driven refinement of blast parameters, the study reveals how this framework was used to address the quarry production demand for increased crusher throughput, and reduced processing costs. The existing quarry blast design was assessed as a baseline and compared against the crusher's inlet requirements and the acceptable fines level specified by the quarry. This evaluation aimed to identify and implement modifications to enhance blast performance. A drone (UAV) was employed to capture post-blast images and monitor blast pile displacement. These UAV images were used to generate an orthomosaic image, which was analyzed to assess fragmentation. The orthomosaic was overlaid onto a GIS platform using a 10m-by-10m grid to evaluate fragmentation distribution across the bench and identify areas requiring optimization. Additionally, drone imagery was utilized to monitor the impact of each blast on the subsequent blast's free face and to assess energy utilization for optimizing front-row holes to achieve improved fragmentation. The outcomes of this research offer a replicable methodology for continuous improvement in quarry blasting practices, with a focus on producing fragmentation that aligns with primary crusher requirements.