Waste Walk Observation Training Ruan C. Varney, CT, CQE, SSBB
Objectives To be able to identify: A detailed & clear understanding of the process Road blocks or waste Flow of information/products Defective processes
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
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
Waiting Idle time created when people, information, equipment or materials are not at hand People waiting Up & Downstream inactivity
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
Overproduction Producing more than what s required for the customer Over done Lot full of cars produced by schedule, not demand
Inventory Excessive or insufficient stock at hand storage space, up front cost, validation time, standing orders Insufficient- costly rapid transportation, overtime
Transportation Unnecessary movement of products Specimens moving from one to another
Motion Unnecessary movement of people/staff Searching for patients, information, supplies BEFORE AFTER
Over-Processing Does not add value to customer Rework, redundant steps, clarifying orders 1,2,3,4. MULTIPLE COPIES of PAPERWORK
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
Post Observation & Recommendation 1. Process Defects Spec. label at bed side 2. Overproduction No extra labels 3. Waiting Specimen drop in bin 1x1
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
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
Life of an OR Patient 1. Pre-Surgical testing 2. Checking in for surgery 3. Pre-Op area 4. Operating Room 5. Recovery Room
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
Q & A