11

Lean 6S TrainingLean 6S TrainingMercy Medical CenterMercy Medical Center

5046 LDLEAN6S - Version 8/20/2009

22

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 resultsExamples of Mercy 6S results

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8 Forms of Waste8 Forms of Waste

1.1. WASTED HUMAN TALENTWASTED HUMAN TALENT

2.2. DEFECTSDEFECTS

3.3. INVENTORYINVENTORY

4.4. OVERPRODUCTIONOVERPRODUCTION

5.5. WAITING TIMEWAITING TIME

6.6. MOTIONMOTION

7.7. TRANSPORTATIONTRANSPORTATION

8.8. PROCESSING WASTEPROCESSING WASTE

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Not asking the staff that works the process how to improve it

1. Wasted Human Talent1. Wasted Human Talent

I’ve made a few changes to the

process.

StaffStaff

StaffStaff

StaffStaff

ManagerManager

I wish someone would ask OUR

opinion…!

StaffStaff

StaffStaff

55

@*&#!!

A negative outcome from process failureA negative outcome from process failure

2. Defects2. Defects

Another defect!!

66

Items in greater quantities than can be immediately Items in greater quantities than can be immediately processed or used.processed or used.

3. Inventory3. Inventory

Did I really order this much??

77

Generating more work than is really requiredGenerating more work than is really required

4. Over Production4. Over Production

StaffStaff

Hey…are these multiple orders for the same thing? @#$&*!!

I didn’t get my order yet… I’ll send another

fax.

PharmacistPharmacist

88

People waiting for items (patients, supplies, People waiting for items (patients, supplies, specimens, etc.) to processspecimens, etc.) to process

5. Waiting5. Waiting

99

Unnecessary human movementUnnecessary human movement

6. Motion6. MotionWhy can’t I get anything done?

1010

Unnecessary movement or relocation of itemsUnnecessary movement or relocation of items

7. Transportation7. Transportation

I have orders to run some tests.I’ll bring the

patient right over.

Waiting Area

Sigh…..!!

1111

8. Over Processing8. Over Processing

Please approve.

Please approve.

Please approve.

Please approve.

Please approve.

Please approve.

1212

8. Over Processing8. Over Processing

I’m the final approval.

The final approval?!!

Applying effort to activities that are not required Applying effort to activities that are not required in the processin the process

Please approve.

+

???

1313

1.1. SortSort

2.2. StraightenStraighten

3.3. ScrubScrub

4.4. StandardizeStandardize

5.5. SustainSustain

What is 6S?What is 6S?

6.6. SafetySafety

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Step 1: SortStep 1: Sort

Separate the needed from the not neededSeparate the needed from the not needed

Before After

1515

Step 2: StraightenStep 2: Straighten

A place for everything & everything in its place!

BEFOREBEFORE AFTERAFTER

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Step 3: Scrub (inspect)Step 3: Scrub (inspect)

Regularly “scrub” to ensure everything is in Regularly “scrub” to ensure everything is in perfect working conditionperfect working condition

“Scrub” and inspect equipment to ensure it is in perfect working condition...

Add inspecting equipment into your work routine.

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Step 4: StandardizeStep 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.

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Visual Controls ensure that Visual Controls ensure that anyoneanyone can find what they can find what they need in a matter of moments.need in a matter of moments.

Note labels and Note labels and instructionsinstructions

Step 4: StandardizeStep 4: Standardize

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Step 5: SustainStep 5: Sustain

Develop a method for sustaining your gainsDevelop a method for sustaining your gains

2020

Step 6: SafetyStep 6: Safety

Safety is a top priority in all that you do!Safety is a top priority in all that you do!

Safety first when determining where items Safety first when determining where items are to be located:are to be located: Keep fire hydrants clearKeep fire hydrants clear

Electrical a safe distance from plumbing Electrical a safe distance from plumbing

All items accessible - Not too high, not too lowAll items accessible - Not too high, not too low

Uncluttered traffic areas - no tripping hazardsUncluttered traffic areas - no tripping hazards

Emergency phone numbers and procedures Emergency phone numbers and procedures prominently postedprominently posted

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How do I Conduct a 6S?How do I Conduct a 6S?

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Preparation Preparation

Observe the process first hand (Gemba Observe the process first hand (Gemba walk)walk)

Create a spaghetti diagram - Create a spaghetti diagram - a hand a hand drawn map of your process including:drawn map of your process including: Tasks in the sequence they are done Tasks in the sequence they are done Location of supplies and equipmentLocation of supplies and equipment Measure distance traveled and time spent Measure distance traveled and time spent

searching or waitingsearching or waiting

Good preparation is the key to successful results!Good preparation is the key to successful results!

2323What forms of “Waste” can you identify?

AncillaryTesting

Supply Room

ChartRack

TubeStation

Printer

Patient’s Room

Nurse’s Station

Med Room

ReportRoom

200 feet

100 feet

150 feet

250 feet

200 feet

150 feet

200 feet

300 feet

1,550 Feet

Time & Distance Traveled - Before

Spaghetti DiagramSpaghetti Diagram

Dedicated Staff

108 min

16 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 – searchingFor printer paper

10 min – waiting for

meds tube system

10 min – searching

for PT chart

2424

What would you do to improve?What would you do to improve?

Sort out the need from the not neededSort out the need from the not needed

Have a place for everything so there is no searchingHave a place for everything so there is no searching

Move supplies or equipment closer to where they are Move supplies or equipment closer to where they are neededneeded

Co-locate tasks or peopleCo-locate tasks or people

Change the sequence in which tasks are doneChange the sequence in which tasks are done

Be creative with your solutions – you, after all, are Be creative with your solutions – you, after all, are the expert!the expert!

How Can We Improve?How Can We Improve?

Applying 6S eliminates waste!

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Spaghetti DiagramSpaghetti Diagram

No Searching or Waiting - AfterNo Searching or Waiting - After

Reduced travel by 1150 ft & search time by 68 min.Reduced travel by 1150 ft & search time by 68 min.

Chart Rack

AncillaryTesting Printer

TubeStation

Nurse’sStation

Patient’sRoom

Med Room

Supply Room

ReportRoom

30 sec – 6S on

supply room

60 sec – 6S on

Med room

Dedicated Staff

I’ve found my “dream” job!

40 min

1.5 min

2 min

1.5 min

1.5 min

1.5 min

1 min

30 min

1 min

30 sec –

6S on

chart r

ack

30 sec – Paper checked

@ end of each shift

30 sec – Indicator light

installed on tube system

400 ft

50 feet

50 feet

50 feet

50 feet

50 feet

50 feet

50 feet

50 feet

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

2727

Simulation – Round 1Simulation – Round 1

2828

Instructions to the ClassInstructions to the ClassWorkerWorker Gather White, Yellow and Blue sheets of paperGather White, Yellow and Blue sheets of paper Paper clip the sheets together Paper clip the sheets together Place in a folderPlace in a folder Place post-it on the outside of the folderPlace post-it on the outside of the folder Place folder and contents on the chair (to be picked up by Place folder and contents on the chair (to be picked up by

a delivery person)a delivery person)

ManagerManager Create a spaghetti diagram:Create a spaghetti diagram: Draw the room layout, identifying the location of the Draw the room layout, identifying the location of the

supplies used in the simulationsupplies used in the simulation As Participant #1 walks the process, trace his/her As Participant #1 walks the process, trace his/her

footsteps on the spaghetti diagramfootsteps on the spaghetti diagram

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Instructions to the ClassInstructions to the Class

Efficiency Expert #1Efficiency Expert #1 Count the number of steps Person #1 travels from beginning to Count the number of steps Person #1 travels from beginning to

end in the process.end in the process.

Efficiency Expert #2 Efficiency Expert #2 Track how much time Participant #1 takes to do the entire Track how much time Participant #1 takes to do the entire

processprocess Track how much time is wasted waiting and/or searchingTrack how much time is wasted waiting and/or searching

CustomerCustomer Do a quality inspection on the finished product against the Do a quality inspection on the finished product against the

sample provided to you by the Instructorsample provided to you by the Instructor

Co-workers (Rest of Class)Co-workers (Rest of Class) Identify the 8 Forms of Waste in our processIdentify the 8 Forms of Waste in our process Identify possible ideas for improvementIdentify possible ideas for improvement

3030

Quantifying the ResultsQuantifying the Results

Capture the Results from Round 1

3131

What Are the Results?What Are the Results? Manager Manager

What does the spaghetti diagram show us?What does the spaghetti diagram show us?

Efficiency Expert #1Efficiency 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 #2Efficiency 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?

CustomerCustomer Was the customer happy with the service provided (quality Was the customer happy with the service provided (quality

inspection)?inspection)?

Rest of ClassRest of Class Identify forms of waste in the processIdentify forms of waste in the process Include possible ideas for improvementInclude possible ideas for improvement

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What Waste Did You Observe?What Waste Did You Observe?

1.1. Wasted Human TalentWasted Human Talent

2.2. DefectsDefects

3.3. InventoryInventory

4.4. Over ProducingOver Producing

5.5. WaitingWaiting

6.6. MotionMotion

7.7. TransportationTransportation

8.8. Over ProcessingOver Processing

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How Can We Use 6S to Improve?How Can We Use 6S to Improve?

1.1. SortSort – – Separate the needed from the not neededSeparate the needed from the not needed

2.2. StraightenStraighten – – A place for everything and A place for everything and everything in its placeeverything in its place

3.3. ScrubScrub – – Ensure everything is in perfect working Ensure everything is in perfect working conditioncondition

4.4. Standardize – Standardize – Determine the best method – Determine the best method – visual queues, labeling, etc.visual queues, labeling, etc.

5.5. Sustain – Sustain – Develop Standard WorkDevelop Standard Work

6.6. Safety – Safety – Safety first at all timesSafety first at all times

3434

Simulation – Round 2Simulation – Round 2

3535

Instructions to the ClassInstructions to the Class

Now that you have identified the waste and the Now that you have identified the waste and the opportunities for improvement in the processopportunities for improvement in the process

Put your recommended improvements in placePut your recommended improvements in place

We’ll run the simulation a second time We’ll run the simulation a second time

Then we’ll measure the results…Then we’ll measure the results…

……..and celebrate our success!!and celebrate our success!!

3636

Quantifying the ResultsQuantifying the Results

Capture the Results from Round 2