7/17/2012. Welcome! Topic: Lean Six Sigma How Can it Help Your CSSD? Facilitators: Diane Koch 3M Susan Flynn 3M

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1 3M Sterile U Network 3M Sterile U Web Meeting July 19, 2012 Lean Six Sigma How Can it Help Your CSSD? Today s meeting times: 9:00 a.m., 11:00 a.m. and 1:00 p.m. CST 1 To hear audio, call and enter access code Phone lines are muted. Audio will commence when the webinar begins. Introducing the 3M Learning Connection: New Name, Same Great Courses It s an educational resource bringing you 3M Sterile U and other Infection Prevention courses. You ll soon see some exciting new benefits as our program evolves! Improved features: Add to my Calendar feature added this month! Other 3M courses will be more accessible as we expand our offerings. What do you need to do? Nothing. Your current registrations remain and our Sterile U offerings have not changed. 2 Welcome! Topic: Lean Six Sigma How Can it Help Your CSSD? Facilitators: Diane Koch 3M Susan Flynn 3M Speaker: Jeff Asproth, Supply Chain Manager 3M Housekeeping Questions Mute feature (*7 = unmute; *6 = mute) Chat feature Technical difficulties Post session follow-up 3For more information: 1

2 How do I get a CE Certificate? Next week, all of today s meeting participants will be sent an containing instructions for obtaining a CE Certificate for today s meeting. The will be sent to the address you provided when you logged-in to today s meeting. If there are others listening with you today who did not log-on, you may forward the CE certificate to them. 4 Disclosure Statement Jeff Asproth Supply Chain Manager 3M Infection Prevention Division 3M Center, St. Paul, MN Facility pictures taken with permission during 3M Six Sigma on-site project work 5 About the presenter: Jeff Asproth 12 years in 3M Health Care Certified Lean Six Sigma Black Belt Led Lean Kaizen projects in Sterile Processing to optimize work flow & reduce waste Experienced in Supply Chain and Manufacturing Scheduling systems, production & process flow Project Management Led production line moves & scale up Led PPU (Product & Process Understanding) APICS (American Production & Inventory Control Society) CPIM (Certified in Production & Inventory Management) 6 2

3 Learning Objectives Understand the basics of Lean Six Sigma philosophy Review universal applications of Lean Six Sigma practices in a sterile processing department Indentify opportunities to implement in Lean Six Sigma practices in a sterile processing department Understand the process of implementing Lean Six Sigma in a sterile processing department 7 Presentation Outline About Lean & Six Sigma Lean in Healthcare Lean in Sterile Processing Goals Process Map Examples of using Lean & 5S 8 Lean in Healthcare Lean has expanded to many areas of Healthcare including: Operating room When lean changes were enforced, turnover time dropped 30 per cent to 29 minutes and turnaround time dropped 20 per cent to 69 minutes. Automated alerts to janitorial staff cut room cleaning times - The Toronto Star Emergency room St. Joseph s Hospital changed the ER patient flow, allowing the hospital to treat at least 10,000 more patients annually. Tampa Bay Business Journal Nurse stations St. Vincent Indianapolis Hospital made a 78% cut in the number of steps emergency department nurses take to get supplies. USA Today Prescriptions North Mississippi Medical Center reduced the number of prescription errors in discharge documents by 50%. ASQ.org(American Society for Quality) Many others billing, patient discharge, sterile processing, etc. 9 3

4 Let s get Lean! "Lean," is a practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination Working from the perspective of the customer who consumes a product or service, "value" is defined as any action or process that a customer would be willing to pay for Lean thinking is the identification and steady elimination of waste (muda). Lean is a problem solving approach for continuous daily improvement Kaizen Japanese for improvement or change for the better Six Sigma Seeks to improve the quality of output by identifying and removing the cause of defects and minimizing variability in manufacturing and business processes. Six Sigma uses a set of quality management methods and statistical methods with a defined sequence of steps 10 7 Types of Muda Tim Wood Transport (moving products that are not actually required to perform the processing) Inventory (all components, work in process and finished product not being processed) Motion (people or equipment moving or walking more than is required to perform the processing) Waiting (waiting for the next production step) Overproduction (production ahead of demand) Over Processing (resulting from poor tool or product design creating activity) Defects (the effort involved in inspecting for and fixing defects) Waste of unused human talent (8 th ) 11 Lean in Sterile Processing: Goals: Identify & Eliminate Waste Transportation, Inventory, Motion, Waiting, Over production, Over production, Defects (rework), Unused talent Reduce / Eliminate Process Variability (Standard Work) Continuous Improvement Drive systematic change sustain the gains 5S Sort, Straighten, Shine, Standardize, Sustain 12 4

5 High Level - Sterile Processing Flow OR Patient Case Request CS - Instruments stored in inventory CS - Patient case is picked and sent to OR CS - Instrument set sterilization OR procedure CS - Instrument set assembly Used instrument sets sent from OR to CS CS - Decontamination & wash 13 Lean Improvement Example Current Process: Tech moves orange cart from washer to case racks Tech unloads orange cart and places empty cases on the storage racks When tech assembles instruments, the tech will go to the storage rack and retrieve an empty case Proposed Future Process: Remove storage rack Orange cart is moved from washer to storage area When tech assembles instruments, the tech retrieves an empty case from the orange cart 2 3 more orange carts will be needed No more double handling of cases 14 Current State Addition of movable instrument t locating pins Add fixtures to instrument basket every instrument has it s place 15 5

6 Patient Case Cart Builds: Soft Goods Case Carts Dumbwaiter to OR Soft Goods Various items: 1 time use consumables Hard Goods Current State: Non-value added steps Containers at all levels Items required for patient case located in all areas of storage No distinction between high volume and low volume items 16 Patient Case Cart Builds Continued: K its and Disposables Kits and Disposables Staged Case Carts by surgery time Dumbwaiter to OR High Volume High Volume Low Volume Low Volume Low Volume Kits and Disposables/Vendor Kits Future State: Stratify items based on usage (high volume procedures) High volume drape packs, instrument cases, and consumables located near the dumbwaiter Low volume drape packs, instrument cases, and consumables placed further away Low Volume 17 5S Examples: 18 6

7 5S Where may it apply to Sterile Processing? Sort instruments by type Sort instruments largest to smallest Let those who use it decide 19 Assembly Table Example Current State: Tech leaves the assembly area to retrieve commonly used supplies from storage rack Future State - Example Move frequently used supplies to the assembly table so they are within arms reach of the Tech 20 Other Examples: Visual Queues to prompt resource loading When more than 3 carts in decontamination add extra resource Use of non-tethered scanners From corded phone to wireless headset Use of transport cart vs. manually carrying instruments From decontamination sink to washer From washer to assembly table 21 7

8 Lean How Can it Help Your CSSD? Take another look at your processes What is truly value added? What shouldn t we be doing? Look for best practices Learn through h trying Your organization already has many ideas! Does your organization have a Lean / Six Sigma person(s) on staff to be another perspective? 22 Key Learnings Basics fundamentals of Lean Six Sigma philosophy Practical applications of Lean Six Sigma in a sterile processing department Indentifying opportunities to remove waste by using Lean Six Sigma practices Understanding the process of implementing Lean Six Sigma in a sterile processing department 23 Thank you! Next 3M Sterile U Web Meeting: Thursday, August 16 th Steam Sterilization ti Challenges Register at