How to Control an Ergonomics Program through Six-Sigma Methodology

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1 How to Control an Ergonomics Program through Six-Sigma Methodology Ana M. Ferreras Keith White, Ph.D., CPE, CEM

2 Agenda Background Ergo-Sigma Model DMAIC Process Steps Tools Conclusion

3 Background Six Sigma is.. a customer focused, well defined problem solving methodology, supported by a hand full of powerful analytical tools. Continuous improvement is driven by the execution of carefully selected projects

4 Ergo-Sigma Structure Management Vision Strategic Planning Six-Sigma DMAIC Daily Control PDCA/Kaizen Teams

5 DMAIC Five Step Process Define Control Measure Improve Analyze

6 Six-Sigma Define Understand the problem (limit scope) Measure Quantify the ergonomics risk factors Analyze Understand the root causes of ergonomics risk factors Improve Determine how to best reduce risk factors, and implement the improvements Control Measure results of the improved process to ensure that improvements have been implemented

7 Is 99% Good Enough? ü15 minutes of unsafe drinking water each day ü5,000 incorrect surgical operations per week ü200,000 wrong drug prescriptions each year üno electricity for almost 7 hours each month Capability 3 Sigma 4 Sigma 6 Sigma Long-Term Yield 93.32% 99.38% % Standard Historical Standard Current Standard New Standard

8 Effective Six Sigma must 1. Ergonomics program must exist and be in use. You can t improve a process that doesn t exist 2. The program must be in control statistically. Must have some track record of performance 3. The program may then be improved. Reduce risk factors in the process

9 DMAIC Stage Goal setting of sub-teams Identifying stakeholders Select team and assign task/accountabilities Discuss with workers to obtain information Start identifying factors and concerns

10 Define Tools Project Charter FlowChart/Task Mapping Stakeholder Analysis Benchmarking Analysis

11 DMAIC Stage Measure current ergonomic program Initial data gathered Categorize initial data Perform an analysis to identify high impact areas Develop performance metrics & project scorecard Perform ergonomic evaluations of work tasks and work environment

12 Measure Tools Critical to Quality (CTQ) Histograms Pareto Charts Assessments (Office, Lifting, Hands & Arms) Checklist

13 Initial problem analysis DMAIC Stage Develop cause and effect relationships Determine and validate root causes Investigate and quantify job requirements Analysis of human performance and physiological response

14 Analyze Tools Cause and Effect Analysis (Ishikawa diagram) Failure Mode & Effect Analysis (FMEA) Design of Experiments (DOE) Prioritization Matrix

15 DMAIC Stage Identify breakthroughs and select practical approaches Gain approval to implement improvements Design or redesign strategies Implement ergonomic intervention Establish medical control policies Train management, supervision, and workers in correct methods and sources of problems

16 Improve Tools Ergonomic Training Video Tapes Assessments (Office, Lifting, Hand & Arms) Checklist Cost-Benefit Analysis Responsibility Matrix Quality Function Deployment

17 DMAIC Stage Measure results, develop control methods and manage change Report scorecard data & create a process control plan Continually improve the process P-D-C-A cycle is repeated (Kaizen events) Focus on engineering and administrative controls Educate employees through training

18 Balanced Scorecard Checklist Assessments Histograms Pareto Charts Control Tools

19 Systemic approach Ergo-Sigma framework Conclusion Continuous improvement Quantitative tools to identify ergonomics root causes Control, improve, and predict risk factors

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