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Lean Journey Begins with Keys to Kaizen & a Path to Prefab
October 17th, 2019
Victoria Navarro, Advocate Aurora Health
Dave Mikos, Anderson Mikos Architects
Josh Odelson, Power Construction
Chris TenEyck, Connelly Electric
O V E R C O M I N G O U R I N D U S T R Y C H A L L E N G E S W I T H L E A N S O L U T I O N S
2 1 ST AN N U A L
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O V E R C O M I N G O U R I N D U S T R Y C H A L L E N G E S W I T H L E A N S O L U T I O N S
Speakers
• Victoria Navarro
– Regional Director of Planning, Design
& Construction at Advocate Aurora Health
• Josh Odelson
– Senior Project Manager at Power Construction
• Dave Mikos AIA, ACHA
– Chairman & CEO of Anderson Mikos Architects, ltd.
• Chris TenEyck
– Senior Project Manager at Connelly Electric
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Learning Objectives
In this session you will learn about ….
• What is a 3P Kaizen Event?
• Why is this Process Valuable to the Customer?
• How to Implement 3P Kaizen and Develop a Path to Prefab?
• Keys to Success
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Advocate Aurora Health – Lean Journey
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What is Kaizen? Change for Good and Continuous Improvement
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3P – Production Preparation Process
• A rapid cycle Lean process that focuses on generating
lots of ideas; with simultaneous input from all stake
holders up front for the layout of the Procedural Center
Why 3P Kaizen?
• Speed to market - 6 months shorter design schedule
• Operational efficiency through process improvement
• Supports elimination of waste through lean thinking
What is 3P?
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Typical 3P Kaizen Team Members
• Executive Sponsor
• Project Champions
• Nurses
• Physicians
• Clinical Support Staff
• Support Services Leaders
• Architects
• Design Engineers
• Construction Team
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3P Kaizen Schedule Overview
DAY 3DAY 2DAY 1
3P Training
GembaWalk/ Observe & Analyze Current Process
Listen to the VOCs
Design / Evaluate
Evaluate 7 Flows
Decide Best “Parts”
Create Hybrid Design
Final Flows
Final Presentation
Kick-offMeeting
Team Exercise
Value Stream Mapping
M44-6 hours
Visioning Kaizen Event
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Voice Of the Customer (VOC) just ask!
What works well in the current state?
What does not work well?
How would your customer design the future
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Design Process
• Using current layout
• Design multiple ideas to improve flow
• Remember to minimize movements
• Prepare layouts for presentation and voting----QUICKLY
• Flow of patients
• Flow of clinicians
• Flow of medications
• Flow of supplies
• Flow of equipment
• Flow of information
• Flow of process
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Moonshine Design
• 4 Design Concepts Produced
• (6 Design Concepts thrown under the table)
• Voted on 4 Concepts Down to Top 2
• “Moonshine” down to One Design
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The Seven Flows “Its all about FLOW”
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After Three Days of 3P……
Kaizen Day 3 Under Construction
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3P Kaizen Preliminary Results
• Future Metrics – TBD
• Patient Satisfaction
• Associate Satisfaction
• Operation Workflow (Footsteps)
18%6
Months$4M
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Prefab/ Modular Project Vision
Precast Panels
Multi-Trade Racks Prep/Recovery
Pods
Modular Surgical
Ceilings
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Modular: Prep/ Recovery Pods
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Modular: Surgical Ceiling Systems
Stick-Built Vendor A Vendor B
Prefab Typical OR Ceiling System
Material n/a $ 59,344 $ 84,675
Installation - Mechanical n/a $ 6,000 $ 6,000
Installation - Electrical n/a $ 2,500 $ 2,500
Supplementary Steel for OR Ceiling System n/a $ 15,000 $ 15,000
Stick Built Typical OR Ceiling System
HVAC - Supply ductwork and grilles $ 33,000 n/a n/a
Power/Lighting $ 22,500 n/a n/a
Ceiling Grid $ 12,000 n/a n/a
Med Gas System $ 5,000 n/a n/a
Drafting/Coordination (mech) $ 6,300 n/a n/a
Drafting/Coordination (elec) $ - n/a n/a
Supplementary Steel for boom supports $ 8,000 n/a n/a
86,800$ 82,844$ 108,175$
Cost Delta (3,956.00)$
OR Surgical Ceiling System Evaluation
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Prefab: OR Walls
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Prefab: Multi-trade Racks
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Prefab: Multi-trade Racks
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Modular/ Prefab: Metric Tracking
Preliminary Metrics (Based On First Production Runs)
• Multi-trade Racks
• MEP Overhead Install (150 linear feet) – Typical: 20 days
• MEP Overhead Install (150 linear feet) – Racks: 5 days
• 50%+ Reduction in MEP Deck Inserts
• Plumbing – First Run used 82% of typical labor
• HVAC & Medgas – First Run used 80% of typical labor
• Electrical – First Run used 60% of typical labor
• Pods – Electrical Rough-Ins – First Run saw 30% labor reduction
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Prefab/ Modular Project Vision
Prefab OR Walls
Multi-trade RacksPrep/Recovery
Pods
Modular Surgical
CeilingsPrecast Panels
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Prefab/ Modular Project Vision
Proposal Presentation Under Construction
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Keys to Success• Respect for People
• Build Trust Among the Team (The ENTIRE Team)
• Educate entire Owner’s team on value of 3P Kaizen
• Document Future State Operational Processes During Kaizen
• Establish leader for each Prefab/ Modular Line
• Multi-trade Racks – Start modeling them Day 2
• Have FUN!!!
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Contact Us
25
Josh Odelson
Power Construction
Victoria Navarro
Advocate Aurora Health
Chris TenEyck
Connelly Electric
Dave Mikos
Anderson Mikos Architects
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In the spirit of continuous improvement, we would like to remind you to
complete this session’s survey in the Congress app! We look forward to
receiving your feedback. Highest rated presenters will be recognized.
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Prefab: What Does the Future Hold?• WE NEED TO ACTUALLY DO IT!!!
• Prefab MEP Racks get delivered for install on 10/28/19
• Prep/ Recovery Pods get delivered for install on 12/6/19
• OR Walls get delivered for install on 12/13/19
• Cleansuite OR Ceiling Systems get delivered on 12/30/19