Waste Walk. Observation Training. LEAN Training Ruan C. Varney, CT, CQE, SSBB. Henry Ford Production System

Transcription

1 Waste Walk Observation Training Ruan C. Varney, CT, CQE, SSBB

2 Objectives To be able to identify: A detailed & clear understanding of the process Road blocks or waste Flow of information/products Defective processes

3 Types of Waste to be Identified Waiting- wasted time between steps Defects- process & product mistakes Transportation- unnecessary movement of material & products Overproduction- more than needed Over-processing- redundant steps, rework Motion- unnecessary movement of people Inventory- over or under stock

4 Where to Observe? Where are the defects happening? Activity: How work is done? Connection: The hand-off? Pathway: How does it flow? Supplier Customer What is the customer s need? How to supply it? How are the requests made? How do we respond? Who supplies what to whom? Direct or with forks? Supplier Observe the work cells Information Products Customer

5 Waiting Idle time created when people, information, equipment or materials are not at hand People waiting Up & Downstream inactivity

6 Process Defects Any activity that does not conform to customer s specification, or expectation It s a process mistake, does not add value Rejected xx

7 Overproduction Producing more than what s required for the customer Over done Lot full of cars produced by schedule, not demand

8 Inventory Excessive or insufficient stock at hand storage space, up front cost, validation time, standing orders Insufficient- costly rapid transportation, overtime

9 Transportation Unnecessary movement of products Specimens moving from one to another

10 Motion Unnecessary movement of people/staff Searching for patients, information, supplies BEFORE AFTER

11 Over-Processing Does not add value to customer Rework, redundant steps, clarifying orders 1,2,3,4. MULTIPLE COPIES of PAPERWORK

12 Effective Observation Stamper Specimen Bin Communicate to staff when, who, why Engage blame free 1 2 Observation of an OB/GYN clinic 3 4 communication about the process Follow the process Engage staff Document findings Collect data/facts Thank the staff for their time

13 Post Observation & Recommendation 1. Process Defects Spec. label at bed side 2. Overproduction No extra labels 3. Waiting Specimen drop in bin 1x1

14 Part II Introduction Observation Exercise Video exercise Identify the Types of waste in each section Who is the Customer & Supplier How would you eliminate it? NEXT STEP: A3 Writing, problem solving

15 Life of A Specimen 1. Specimen arrival & sorting 2. Delivery to surgical pathology 3. Verifying & tracking of specimens 4. Accessioning & Grossing of specimen 5. Processing of specimen

16 Life of an OR Patient 1. Pre-Surgical testing 2. Checking in for surgery 3. Pre-Op area 4. Operating Room 5. Recovery Room

17 Take Home Lessons Direct observation is necessary: To understand how the work is actually done To identify waste & the conditions that cause them To document all steps in detail To identify opportunities for improvement

18 Q & A