5s visual work reorganization - national rural health ... · 1. waiting idle time created when...

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Definition of models

Key Concepts

History

7 Wastes

Observation

5S Visual Work Reorganization

Spaghetti Diagram

An old Chinese proverb states:

“You can’t do today’s job with

yesterday’s methods and be in business tomorrow.”

A continual improvement process, also often called a continuous improvement process (abbreviated as CIP or CI ), is an ongoing effort to improve products, services, or processes.

These efforts can seek "incremental" (Lean) improvement over time or "breakthrough" (Six Sigma) improvement all at once. Processes are constantly evaluated and improved in the light of their efficiency, effectiveness and flexibility.

Lean

Six Sigma (DMAIC)

Baldridge

ISO

Customer

Driven

Focus on the customer

Identify and understand how the work gets done (the value stream)

Manage, improve and smooth the process flow

Remove Non-Value-Added steps and waste

Manage by fact and reduce variation

Involve and equip the people in the process

Undertake improvement in a systematic way

Lean is:

Relentless reduction of waste from the point of view of the customer

Identifying areas for improvement

Streamlining processes/process improvement

Creating greater customer value and increasing employee satisfaction with less work

Improving quality and timely delivery

An intense process analysis linked to customer needs to create more value from the same resources.

James P. Womack

“If you can't describe whatyou are doing as a process,

you don't know what you're doing.”

W. Edwards Deming

Lean is about the process, not the person

Lean is easy to implement at the frontline

Lean application reveals quick and effective results

Lean is a proven methodology for

process improvement and employee satisfaction

• Lean is focused on eliminating waste(Muda) in processes

• Lean is not about eliminating people

• Lean is about understanding what is important to the customer

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Lean provides tangible (measurable) benefits

Reduces costs & Improves quality

Improves customer rating, perception, and overall satisfaction

Improves employee involvement, morale, and company culture

Helps “transform” organizations

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Anything other than the minimum amount of:

Equipment

Materials

Parts

Space

Worker’s time

which are absolutely essential to add value to the product.

1. Waiting Idle time created when people, information, equipment

or materials are not at hand

2. Over Production Redundant work

3. Over Processing Activities that do not add value from the

patient/customer perspective

4. Defects/Errors Work that contains errors or lacks something of value

5. Travel/Motion Movement of people or goods that do not add value

6. Inventory More materials on hand than are required to do the work

7. Confusion People doing the work are not confident about the best was to perform the task

8. Under utilized human creativity

◦ Cindy Jimmerson Lean Health West

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Observation

Value Stream Mapping

5S Visual Work Reorganization

Spaghetti Diagram

Basketball DVD

Two teams – one wearing white shirts and the other black shirts.

Count how many successful passes the white team makes.

Please do not speak.

Write your number down on a piece of paper.

A Value Stream Map

is a visual representation of the process that includes: Information on time Quality Resources and most importantly, allows us to analyze

Value Added and Non-Value Added activity

Finding Opportunities With Lean Value Stream Mapping

Organizations that use Lean often have a “Kaizen” culture, and conduct “Kaizen

Events.” Kaizen is a Japanese word that essentially means “change for the

better.” Kaizen events are events or projects where we will be looking closely at specific processes to make changes

for the better using Lean.

Finding Opportunities With Kaizen & Kaizen Events

SortEliminate what is not needed

Set in Order or StraightenOrganize what remains

ShineClean work area

Safety

Resolve unsafe working conditions

StandardizeSchedule cleaning and maintaining

SustainMake New 6S a way of life

5/6S Workplace Organization

SORT

SET

IN

ORDER

SHINE

STANDARDIZE

SUSTAIN

SAFETY

Consistency and self-discipline for sustainability

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Lack of organization and standardization creates waste, frustration and

opportunities for defects

Why Sort is important – Clean, orderly workplace

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Why Sort is important – Clean, Orderly workplace

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What is a project charter?

A project charter is a written document (usually on a single page) that describes what is the

project all about, why we are working on this project, what is the timeline and who are team

members working on this project. A project charter contains six main elements (and you can add

more to this list if required by your company):

Business Case: The business case describes why this project is important to the company. Why

should the management support this?

Problem Statement: The problem statement contains a brief description of what is the “pain”

being experienced by the company. You need to relate the problem statement to the voice of the

customer (whether internal or external).

Goal Statement: What is the goal of the project? How much improvement are we targeting? The

goal of the project should be specific, measurable and time bound..

Scope Statement: The scope of the project clearly describes what is included in the project and

what is excluded in the project. Scope can include product families, geographical areas,

departments etc.

Timeline: The timeline describes the key milestones and when they will be completed.

Team Members: Team members section includes all the resources that are required to work on

this project. Typically, mentioned in this section are the project sponsor, key stakeholders, team

members, subject matter experts.

Sigmamagic.com

SortKeep only what is needed, when it is needed,

only in the amounts needed

• Straighten

• Eliminate excess materials and equipment

• Remove unnecessary items

Set in OrderA Place for Everything, and Everything in its Place

Planning to ensure things are placed where they need to be to eliminate as much waste as possible

Placing things in their “home” A shared understanding of:◦ Where things belong◦ What things belong where

ShineEveryone should see the workplace

through the eyes of the visitor

• Identify targets and assignments

• Determine cleaning methods

• Perform cleaning of everything

• Red tag / replace worn equipment

Get your team together

Establish a local red tag holding area

Set red-tag criteria

Evaluate items and attach red tags

Plan for disposal of red tagged items

Document the results –Disposition List

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Found something in your work area but are not sure of the use or need?

SafetyIt's a very sobering feeling to be up in space and realize that one's safety factor was determined by the lowest bidder on a

government contract. Alan Shepard

Identify targets and assignments• Determine cleaning methods

• Perform cleaning of everything

• Red tag / replace worn equipment

StandardizeStandardization is a state that exists when sort, set in

order, shine and the safety inspection are fully maintained.

• Standardization can only be done once you have successfully completed the initial 4 pillars

• Establish guidelines• Make the standard conditions visual• Maintain and monitor conditions

SustainThere are three types of innovations that affect jobs and capital: empowering innovations, sustaining innovations and efficiency

innovations. Clayton M. Christensen

Purpose is to maintain your gains. Make your changes a “Habit.” Total employee involvement Management support Develop awareness Ongoing, facility wide communication Make Workplace Organization standards part of daily

work

Define visual workplace re-organization

Physical Change

1. Sort

2. Set in Order

3. Shine

4. Safety

Cultural Change

5. Standardize

6. Sustain

A spaghetti is a method of viewing data to visualize possible flows through systems. Flows depicted in this manner appear like noodles, hence the coining of this term.[

This method of statistics was first used to track routing through factories. Visualizing flow in this manner can reduce inefficiency within the flow of a system.

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Principles of Lean

•See things through the eyes of the customer

•Find a better way of doing things•Look at the entire picture•Respect the ideas and work of others•Give staff the time and tools to make

the necessary improvements•Take small steps as well as big leaps