project and certification approval processes kaizen event black ink ops: ramiro jara, paul koelle,...

Project and Certification Approval Processes Kaizen Event

Black Ink Ops:Ramiro Jara, Paul Koelle, Willis Read-Button, Jessica Watkins

Report Out for May 12, 2010 MGMT E-5060

• Global manufacturer of medical devices and pharmaceuticals

• 42,000 employees with 58 manufacturing facilities located in 16 countries

• 2009 Sales – $10.9 BB

Medical DevicesEndomechanical, Energy,

Airway, Soft Tissue Repair, OximetryPharmceuticals

Specialty Pharma, Contrast, Radiopharma

Medical SuppliesOR, Nursing Care,

SharpSafety

About Covidien

Covidien / Black Ink Ops | May 12, 2010 | Confidential2 |

Master Black Belt 44

Black Belt 367

Green Belt 861

Lean Leader 374

OpEx Program Savings to Date:

OpEx Program Certifications to Date:

> $1.2 BB


Kaizen Event Daily Structure


• Focused 5-day, team-based, action-oriented activity focused on one discrete improvement effort

• Part of Value Stream Analysis of strategic processes• 4-6 people in a team, devoted to the effort for the week• Change is implemented as part of the Event• ‘Lean Sensei’ coach helps with methodology and learning


Process Overview: Project and Certification Approvals

Candidate

Training

Exam

Corporate OpEx

Certification

Project #2

Certification Request

Project #1

Approval

Scope

Paper Based FormsProject Tracking - Instantis

Current State Process


Multitude of StepsLong Lead Time

Current State Value Stream Map (VSM)

Covidien | April 19, 2023 | Confidential7 |

Int’l USALead Time: 651.31hrs 650.81hrsCycle Time: 3.31hrs 2.81hrs

First Pass Yield: 50%

Pareto Chart


Batching Projects

Lack Std. Work

Misuse of Tools

Incomplete Forms

Excessive L/T

Root Causes/Solutions

Problem Action

Batching of 1st and 2nd Projects • Begin Monthly Project Reviews• Enable project approvals at local level

Lack of Standard Work • Create standard work guidelines

Misuse of Tools • Create more accountability and mentorship through Monthly Reviews and Quarterly Audits by Corporate OpEx team

• Create Feedback Loop back to training team

Incomplete Forms • Migrate from paper-based to electronic forms with required field lockouts

Excessive Lead Time • Migrate from paper-based to electronic forms for improved stakeholder access

• Improve ability to access forms and approve during travel

• Eliminate redundant sign-offs and touches


Future State VSM


Lead Time: 48.95 hrsCycle Time: 0.95 hrs

First Pass Yield: >90%

VSM Side-by-Side


Cur

rent

Fut

ure

Hand-off Diagram Side-by-Side: Project Approval


Current Future

Hand-off Diagram Side-by-Side: Certification Approval


Current Future

Metrics Side-by-Side

Current State Future State Change

Cycle Time 3.31 hrs 0.95 hrs ▼71%

Lead Time 651.31 hrs 48.5 hrs ▼93%

Value Added Time 0.50% 27.98% ▲5596%

First Pass Yield 50% >90% ▲>40%

Touches 33 9-10 ▼70%

# of Forms 6 2 ▼66%

# of Signatures 11 7 ▼36%

Annual Savings n/a $117,398* ▲


*Corporate OpEx team savings based on current salary numbers.

The Softer Side of Savings

• Opportunity to find and catch project defects earlier in process

• Improved mentorship from OpEx Directors to OpEx Managers/Leaders in the plant, and eventually to candidates

• Accountability and performance tracking with better metrics, data collection, and report out capability

• Empowerment of GBU and Plant OpEx personnel

• Job satisfaction which results in less turnover

• Environmental responsibility (less paper/toner waste)



In progress

Complete

Scheduled

Workstream 1: Value Stream Analysis and Certification Kaizen

Kaizen #1 to document and analyze VS

Roll out at one GBU for Testing Phase

May 12 AugustJune 15

Implementation Timeline

July 15

Future Kaizen Events: Monthly Review, Qtrly. Audit, DFSS

Train and roll out company-wide to 58 plants

May-July

IS develops eForms

Run pilot in Texas plant

May 14

Workstream 2: Additional Kaizen Events

Q&A


Appendix



Our team at work…

project and certification approval processes kaizen event black ink ops: ramiro jara, paul koelle,...

Documents

project approval covidien

confidential3 slide

confidential9 slide

learning slide

confidential2 slide

bb covidien black ink

touches covidien

approval scope slide