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1 Lean 6S Training Mercy Medical Center 5046 LDLEAN6S - Version 8/20/2009.

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Presentation on theme: "1 Lean 6S Training Mercy Medical Center 5046 LDLEAN6S - Version 8/20/2009."— Presentation transcript:

1 1 Lean 6S Training Mercy Medical Center 5046 LDLEAN6S - Version 8/20/2009

2 2 What are the 8 Forms of Waste? What are the 8 Forms of Waste? What is 6S? What is 6S? How do I conduct a 6S? How do I conduct a 6S? Examples of Mercy 6S results Examples of Mercy 6S results

3 3 8 Forms of Waste 8 Forms of Waste 1. WASTED HUMAN TALENT 2. DEFECTS 3. INVENTORY 4. OVERPRODUCTION 5. WAITING TIME 6. MOTION 7. TRANSPORTATION 8. PROCESSING WASTE

4 4 Not asking the staff that works the process how to improve it 1. Wasted Human Talent Ive made a few changes to the process. Staff Staff Staff Manager I wish someone would ask OUR opinion…! Staff Staff

5 5 @*&#! ! A negative outcome from process failure 2. Defects Another defect!!

6 6 Items in greater quantities than can be immediately processed or used. 3. Inventory Did I really order this much??

7 7 Generating more work than is really required 4. Over Production Staff Hey…are these multiple orders for the same thing? @#$&*!! I didnt get my order yet… Ill send another fax. Pharmacist

8 8 People waiting for items (patients, supplies, specimens, etc.) to process 5. Waiting

9 9 Unnecessary human movement 6. Motion Why cant I get anything done?

10 10 Unnecessary movement or relocation of items 7. Transportation I have orders to run some tests. Ill bring the patient right over. Waiting Area Sigh…..!!

11 11 8. Over Processing Please approve.

12 12 8. Over Processing Im the final approval. The final approval?!! Applying effort to activities that are not required in the process Please approve. + ?? ?

13 13 1. Sort 2. Straighten 3. Scrub 4. Standardize 5. Sustain What is 6S? 6. Safety

14 14 Step 1: Sort Step 1: Sort Separate the needed from the not needed Before After

15 15 Step 2: Straighten A place for everything & everything in its place! BEFORE AFTER

16 16 Step 3: Scrub (inspect) Step 3: Scrub (inspect) Regularly scrub to ensure everything is in perfect working condition Scrub and inspect equipment to ensure it is in perfect working condition... Add inspecting equipment into your work routine.

17 17 Step 4: Standardize Step 4: Standardize Standard Work requires determining the best method then following that method every time. Note: Blue taped outlines and labels ensure equipment is quickly found and returned to the same spot every time.

18 18 Visual Controls ensure that anyone can find what they need in a matter of moments. Note labels and instructions Step 4: Standardize

19 19 Step 5: Sustain Develop a method for sustaining your gains

20 20 Step 6: Safety Safety is a top priority in all that you do! Safety first when determining where items are to be located: Safety first when determining where items are to be located: Keep fire hydrants clear Keep fire hydrants clear Electrical a safe distance from plumbing Electrical a safe distance from plumbing All items accessible - Not too high, not too low All items accessible - Not too high, not too low Uncluttered traffic areas - no tripping hazards Uncluttered traffic areas - no tripping hazards Emergency phone numbers and procedures prominently posted Emergency phone numbers and procedures prominently posted

21 21 How do I Conduct a 6S?

22 22 Preparation Preparation Observe the process first hand (Gemba walk) Observe the process first hand (Gemba walk) Create a spaghetti diagram - a hand drawn map of your process including: Create a spaghetti diagram - a hand drawn map of your process including: Tasks in the sequence they are done Tasks in the sequence they are done Location of supplies and equipment Location of supplies and equipment Measure distance traveled and time spent searching or waiting Measure distance traveled and time spent searching or waiting Good preparation is the key to successful results!

23 23 What forms of Waste can you identify? Ancillary Testing Supply Room Chart Rack Tube Station Printer Patients Room Nurses Station Med Room Report Room 200 feet 100 feet 150 feet 250 feet 200 feet 150 feet 200 feet 300 feet 1,550 Feet Time & Distance Traveled - Before Spaghetti Diagram Dedicated Staff 108 min 16 min 11 min 21 min 11 min 1 min 31 min 1 min 15 min – searching For supplies 15 min – searching for meds 20 min – searching For printer paper 10 min – waiting for meds tube system 10 min – searching for PT chart

24 24 What would you do to improve? What would you do to improve? Sort out the need from the not needed Sort out the need from the not needed Have a place for everything so there is no searching Have a place for everything so there is no searching Move supplies or equipment closer to where they are needed Move supplies or equipment closer to where they are needed Co-locate tasks or people Co-locate tasks or people Change the sequence in which tasks are done Change the sequence in which tasks are done Be creative with your solutions – you, after all, are the expert! Be creative with your solutions – you, after all, are the expert! How Can We Improve? Applying 6S eliminates waste!

25 25 Spaghetti Diagram No Searching or Waiting - After Reduced travel by 1150 ft & search time by 68 min. Chart Rack Ancillary Testing Printer Tube Station Nurses Station Patients Room Med Room Supply Room Report Room 30 sec – 6S on supply room 60 sec – 6S on Med room Dedicated Staff Ive found my dream job! 40 min 1.5 min 2 min 1.5 min 1 min 30 min 1 min 30 sec – 6S on chart rack 30 sec – Paper checked @ end of each shift 30 sec – Indicator light installed on tube system 400 ft 50 feet

26 26 Suggest you insert some before and after pictures/examples of 6S results in the next few slides. Suggest you insert some before and after pictures/examples of 6S results in the next few slides.

27 27 Simulation – Round 1 Simulation – Round 1

28 28 Instructions to the Class Worker Gather White, Yellow and Blue sheets of paper Gather White, Yellow and Blue sheets of paper Paper clip the sheets together Paper clip the sheets together Place in a folder Place in a folder Place post-it on the outside of the folder Place post-it on the outside of the folder Place folder and contents on the chair (to be picked up by a delivery person) Place folder and contents on the chair (to be picked up by a delivery person)Manager Create a spaghetti diagram: Create a spaghetti diagram: Draw the room layout, identifying the location of the supplies used in the simulation Draw the room layout, identifying the location of the supplies used in the simulation As Participant #1 walks the process, trace his/her footsteps on the spaghetti diagram As Participant #1 walks the process, trace his/her footsteps on the spaghetti diagram

29 29 Instructions to the Class Efficiency Expert #1 Efficiency Expert #1 Count the number of steps Person #1 travels from beginning to end in the process. Count the number of steps Person #1 travels from beginning to end in the process. Efficiency Expert #2 Efficiency Expert #2 Track how much time Participant #1 takes to do the entire process Track how much time Participant #1 takes to do the entire process Track how much time is wasted waiting and/or searching Track how much time is wasted waiting and/or searching Customer Customer Do a quality inspection on the finished product against the sample provided to you by the Instructor Do a quality inspection on the finished product against the sample provided to you by the Instructor Co-workers (Rest of Class) Co-workers (Rest of Class) Identify the 8 Forms of Waste in our process Identify the 8 Forms of Waste in our process Identify possible ideas for improvement Identify possible ideas for improvement

30 30 Quantifying the Results Capture the Results from Round 1

31 31 What Are the Results? Manager Manager What does the spaghetti diagram show us? What does the spaghetti diagram show us? Efficiency Expert #1 Efficiency Expert #1 How many steps did it take for the worker to do the process? How many steps did it take for the worker to do the process? Efficiency Expert #2 Efficiency Expert #2 How much time did the entire process take? How much time did the entire process take? How much time was wasted waiting and/or searching? How much time was wasted waiting and/or searching? Customer Customer Was the customer happy with the service provided (quality inspection)? Was the customer happy with the service provided (quality inspection)? Rest of Class Rest of Class Identify forms of waste in the process Identify forms of waste in the process Include possible ideas for improvement Include possible ideas for improvement

32 32 What Waste Did You Observe? 1. Wasted Human Talent 2. Defects 3. Inventory 4. Over Producing 5. Waiting 6. Motion 7. Transportation 8. Over Processing

33 33 How Can We Use 6S to Improve? 1. Sort – Separate the needed from the not needed 2. Straighten – A place for everything and everything in its place 3. Scrub – Ensure everything is in perfect working condition 4. Standardize – Determine the best method – visual queues, labeling, etc. 5. Sustain – Develop Standard Work 6. Safety – Safety first at all times

34 34 Simulation – Round 2 Simulation – Round 2

35 35 Instructions to the Class Now that you have identified the waste and the opportunities for improvement in the process Now that you have identified the waste and the opportunities for improvement in the process Put your recommended improvements in place Put your recommended improvements in place Well run the simulation a second time Well run the simulation a second time Then well measure the results… Then well measure the results… ….and celebrate our success!!

36 36 Quantifying the Results Capture the Results from Round 2


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