Continuous Improvement Playbook
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CONTINUOUS IMPROVEMENT CONSULTING 2 First Choice Pocket Guide First Choice Pocket Guide 3
DHL FIRST CHOICE CONTINUOUS IMPROVEMENT CONSULTING 2 First Choice Pocket Guide First Choice Pocket Guide 3 CONTENTS Introduction 4 Methodologies 6 ACT 8 DMAIC 10 Lean 12 Tools 14 5S Methodology 16 5 Why 18 DILO (Day In Life Of) 20 Effort-Benefit-Matrix 22 Spaghetti Diagram 24 More information 27 To simplify the understanding of each tool a standard structure has been used for all tool deep-dives: Goals/Benefit: reasons for applying the tool / what’s in it for me When: recommendation of when tool can be applied Steps: guide on how to apply tool 4 First Choice Pocket Guide First Choice Pocket Guide 5 INTRODUCTION DHL First Choice is a DHL’s worldwide program to drive continuous improvement of processes and services. ‘Everybody, Every Day and Everywhere a little bit Better’ has enabled us to become and remain the first choice of our customers. This passion for continuous improvement is part of our DNA and is anchored in our corporate culture. It has allowed us to be a global market leader in logistics for many years now. We are happy to share our expertise and experience with you; now you too can experience what the First Choice approach can do for your company and your customers. We have already guided many customers in this process. Goal of DHL First Choice The goal is to create greater efficiency in your services and optimize your processes, with the help of our DHL First Choice experts. Improvements that increase your business performance and strengthen trust in your company. It will also positively impact your customer’s experience with your brand. -
Extension of the Lean 5S Methodology to 6S with an Additional Layer to Ensure Occupational Safety and Health Levels
sustainability Article Extension of the Lean 5S Methodology to 6S with An Additional Layer to Ensure Occupational Safety and Health Levels Mariano Jiménez 1,2 , Luis Romero 2,* , Jon Fernández 2, María del Mar Espinosa 2 and Manuel Domínguez 2 1 Department of Mechanical Engineering, Technical School of Engineering—ICAI, Comillas Pontifical University, 25, 28015 Madrid, Spain 2 Design Engineering Area, Industrial Engineering School, National Distance Education University (UNED), 38, 28015 Madrid, Spain * Correspondence: [email protected] Received: 12 June 2019; Accepted: 11 July 2019; Published: 12 July 2019 Abstract: This paper proposes an expansion of the Lean 5S methodology, which includes the concept of Safety–Security as 6S. Implementation was done by a standardized process tested in a pilot area that is part of the Integrated Industrial Manufacturing System Laboratory at the Higher Technical School of Engineering (ICAI). The additional 6S phase (Safety-Security) thoroughly reviews all areas of an industrial plant by analyzing the risks at each workstation, which let employees be fitted out with protection resources depending on each of their personal characteristics and to guarantee the safety of the workstation by strictly complying with occupational safety and health and machinery use standards, which must hold a CE certificate of compliance. The main objective was to increase the scope of 5S methodology to respond to the occupational safety and health needs for machines required in optimizing production processes. It is important to remember that companies must guarantee that their employees use personal protection equipment (PPE) at their work posts or stations that protect them properly from risks to their health and safety and that cannot be prevented or sufficiently limited by using collective means of protection or by adopting work organization measures. -
Application of the 5S-KAIZEN Approach in Improving the Productivity and Quality of the Healthcare System: an Operational Research
Application of the 5S-KAIZEN Approach in Improving the Productivity and Quality of the Healthcare System: An Operational Research Naglaa Abdel Khalek El-Sherbiny1 (MD); Asmaa Younis ELsary1* (MD); Eman H. Ibrahim1 (MD) 1. Department of Public Health, Faculty of Medicine-Fayoum University, Egypt. A R T I C L E I N F O A B S T R A C T Article type: Introduction: Quality is an important index in various aspects of life. The Original Article 5S-KAIZEN method is widely applied for the improvement of work environments. This systematic approach is fundamentally used to enhance the Article history: quality of services in all types of organizations. The present study aimed to Received: 8-Agust-2017 assess the application of the 5S-KAIZEN approach in improving the quality of Accepted: 29-Agust-2017 care provision in hospitals and evaluate its effects on the job satisfaction of the healthcare providers. Keywords: Materials and Methods: This interventional, operational research was Approach conducted at a teaching hospital. In-depth interviews were performed to obtain Operational the viewpoints of the physicians, and group discussions were held for nurses in Quality order to assess their satisfaction with the implementation of the 5S-KAIZEN 5S-KAIZEN approach in the work environment. Staff Results: Patient-hospital cycle time decreased by more than 50% after implementing the 5S-KAIZEN approach. In addition, the healthcare professionals believed that applying the 5S-KAIZEN approach saved time, money, and efforts, while reducing their daily workload and stress. Conclusion: According to the results, the 5S-KAIZEN approach could improve the standards in the healthcare work environment, support the safe practices leading to high-quality and efficient care services, enhance productivity at a low cost, and increase the satisfaction of the healthcare staff with their professional image and communication with the other personnel. -
Lean Process Improvement Assessment
LEAN PROCESS IMPROVEMENT ASSESSMENT INSTRUCTIONS: Read each item, then check a box on the 1-to-5 scale to show how often this occurs in your workplace: If you checked "often" or "very often" then consider: 1 = never 2 = rarely 3 = sometimes 4 = often 5 = very often In my work area, we spend too much time looking for the items we need to do our 5S+ 1 2 3 4 5 1 jobs: files, materials, equipment, and so on. If the physical work area was better 5S+ stands for sort, straighten, shine, standardize, sustain, organized, we’d be more productive and less frustrated. and safety. When we get inputs from customers or from other sources (from paper forms or Poka-Yoke online web forms, for example), we often find that the incoming information is 1 2 3 4 5 From the Japanese term for mistake-proofing, poka-yoke is 2 incomplete or inaccurate. We have to circle back to people to get the information all about putting measures in place to prevent errors from we need. If we received complete information from them the first time around, we’d occurring as a process unfolds. be a lot more efficient. We find ourselves wondering what our customers are thinking. Are we meeting their Voice of the Customer needs and expectations? Are they happy with our work? Are there things we can do 1 2 3 4 5 When it comes to improvement, understanding the 3 to increase their satisfaction? If we had answers to these questions, we could serve customer’s spoken and unspoken requirements is essential. -
Using the DMAIC Process to Direct the Sequencing of Lean/Six Sigma Tools for Successful Project Outcomes
Using the DMAIC Process to Direct the Sequencing of Lean/Six Sigma Tools for Successful Project Outcomes Jim Ellis Certified Master Black Belt J&J Process Excellence Director – US Sales Strategic Accounts [email protected] Intent: Using the DMAIC Process to Direct the Sequencing of Lean/Six Sigma Tools for Successful Project Outcomes The purpose of this presentation is to share with the attendees my experience over the past 5 years using the DMAIC Process how to determine what Lean and/or 6 Sigma tools is the best to use when for assuring successful outcomes of your projects. Learning Objectives: 1.) Clear understanding of DAMIC Process 2.) Clear understanding of which common Lean and 6 Sigma Tools are best used in what stage of DMAIC 3.) Clear understanding of how to assess success for a project and know if you have achieved it. After Attending the attendees will: 1.) Know what the DMAIC process is and how it is applied in project planning 2.) Understand which Lean and 6 Sigma tools are used in what sequence to assure successful project outcomes © 2008 Ortho Clinical Diagnostics The Driving Forces of Change Today’s Healthcare Delivery Challenges… Declining Resources $29.9 Space Vacancy Capital Funds billion Skilled Labor Rates Medicare/Medicaid Reimbursement Laboratory Techs 5.9% Shortfall Imaging Techs 5.9% Pharmacists 8.1% RNs 8.1% Inpatient Admissions2 ED Visits2 Volume New Technology Market Pressures Increasing Pressures © 2008 Ortho Clinical Diagnostics Why are labs changing? “I need to transform my lab!” Why? • 2X Volume • ½ the -
Using Six Sigma and Lean Principles to Improve Laboratory Operations
Using Six Sigma and Lean Principles to Improve Laboratory Operations Big Bang Makeover of the Clinical Laboratory: Key Lessons for Work Flow, Analyzers, and Service Improvements Atlanta, GA Purpose/Objectives • Purpose: – To provide an overview of using Six Sigma and Lean Principles in chartering, designing and implementing a full scale Lean project in a large laboratory setting. • Objectives: – Understand how each phase of DMAIC was used to execute a full scale Lean design effort – Understand which key Lean tools were used in measure/design/implementation – Understand how interactions of physical, process, technological, and organizational changes contribute to a large scale Lean effort. 1 Outline • Who we are • Why Improving Lab Operations is Important to Quest Diagnostics • The Journey • Key Learnings Who we are • Focus: – Patients – Growth – People • Vision: – Dedicated People Improving the Health of Patients Through Unsurpassed Diagnostic Insights • Company Background – 40,000+ Employees – 900+ Clinical Scientist PhDs/MDs – Patient Service Centers – Rapid Response to Esoteric Laboratories – 145 million patient encounters annually • Values: – Quality, Integrity, Innovation, Accountability, Collaboration, Leadership • Six Sigma/Lean Journey – 2000?2008 2 Why Improving Lab Operations is Important to Quest Diagnostics PATIENTS 1. Reduce Patient Anxiety Time 2. Reduce tests not performed PEOPLE 1. Shortage of technical workforce GROWTH 2. Staffing of night shift 1. Improve equipment utilization 3. Improve technical skills 2. Improve productivity 4. Reduce potential blood exposure 3. Improve supply utilization 5. Reduce ergonomic Injuries 6. Improve staff involvement The Journey 3 The Journey – Integrating Six Sigma Design DMAIC DMADV Lean Three Major Improvement Six Sigma Process Methodologies Management Measurement Systems Integration Complex project required adequate training/development Using DMAIC & Lean to Define Project PATIENTS 1. -
Download Complete Curriculum
L E A N S I X S I G M A G R E E N B E LT C O U R S E T O P I C S Copyright ©2019 by Pyzdek Institute, LLC. LEAN SIX SIGMA GREEN BELT COURSE TOPICS LESSON TOPIC Overview A top-level overview of the topics covered in this course What is Six Sigma? A complete overview of Six Sigma Lean Overview 1 Waste and Value Lean Overview 2 Value Streams, Flow and Pull Lean Overview 3 Perfection Recognizing an Linking your Green Belt activities to the organization’s Opportunity vision and goals Choosing the Project- How to pick a winning project using Pareto Analysis Pareto Analysis Assessing Lean Six Sigma How to carefully assess Lean Six Sigma project candidates Project Candidates to assure success Develop the Project Plan 1 Team selection and dynamics; brainstorming; consensus decision making; nominal group technique Develop the Project Plan 2 Stakeholder analysis, communication and planning, cross functional collaboration, and Force Field Analysis Develop the Project Plan 3 Obtain a charter for your project Develop the Project Plan 4 Work breakdown structures, DMAIC tasks, network diagrams Develop the Project Plan 5 Project schedule management; project budget management Develop the Project Plan 6 Obstacle avoidance tactics and management support strategies High Level Maps 1 L-Maps, linking project charter Ys to L-Map processes High Level Maps 2 Mapping the process from supplier to customer (SIPOC) High Level Maps 3 Product family matrix 2 Voice of the Customer (VOC) 1 Kano Model, getting the voice of the customer using the critical incident technique VOC 2-CTQ Specification Link the voice of the customer to the CTQs that drive it Principles of Variation 1 How will I measure success? Are my measurements trustworthy? Scales of measurement, data types, measurement error principles. -
Lean Six Sigma Rapid Cycle Improvement Agenda
Lean Six Sigma Rapid Cycle Improvement Agenda 1. History of Lean and Six Sigma 2. DMAIC 3. Rapid Continuous Improvement – Quick Wins – PDSA – Kaizen Lean Six Sigma Lean Manufacturing Six Sigma (Toyota Production System) DMAIC • T.I.M.W.O.O.D • PROJECT CHARTER • 5S • FMEA • SMED • PDSA/PDCA • TAKT TIME • SWOT • KAN BAN • ROOT CAUSE ANALYSIS • JUST IN TIME • FMEA • ANDON • SIPOC • KAIZEN • PROCESS MAP • VALUE STREAM MAP • STATISTICAL CONTROLS Process Improvement 3 Lean Manufacturing • Lean has been around a long time: – Pioneered by Ford in the early 1900’s (33 hrs from iron ore to finished Model T, almost zero inventory but also zero flexibility!) – Perfected by Toyota post WWII (multiple models/colors/options, rapid setups, Kanban, mistake-proofing, almost zero inventory with maximum flexibility!) • Known by many names: – Toyota Production System – Just-In-Time – Continuous Flow • Outwardly focused on being flexible to meet customer demand, inwardly focused on reducing/eliminating the waste and cost in all processes Six Sigma • Motorola was the first advocate in the 80’s • Six Sigma Black Belt methodology began in late 80’s/early 90’s • Project implementers names includes “Black Belts”, “Top Guns”, “Change Agents”, “Trailblazers”, etc. • Implementers are expected to deliver annual benefits between $500,000 and $1,000,000 through 3-5 projects per year • Outwardly focused on Voice of the Customer, inwardly focused on using statistical tools on projects that yield high return on investment DMAIC Define Measure Analyze Improve Control • Project Charter • Value Stream Mapping • Replenishment Pull/Kanban • Mistake-Proofing/ • Process Constraint ID and • Voice of the Customer • Value of Speed (Process • Stocking Strategy Zero Defects Takt Time Analysis and Kano Analysis Cycle Efficiency / Little’s • Process Flow Improvement • Standard Operating • Cause & Effect Analysis • SIPOC Map Law) • Process Balancing Procedures (SOP’s) • FMEA • Project Valuation / • Operational Definitions • Analytical Batch Sizing • Process Control Plans • Hypothesis Tests/Conf. -
Methods and Concepts for Lean-Powered Improvement
Methods and Concepts for Lean-Powered Improvement DAILY LEAN “Just do it” Easy improvements found in daily work, walk-throughs, events, etc. Huddles Quick team sessions to check work status, make decisions, problem solve Kanban Boards Visual tool to communicate and optimize the flow of work Scorecards and Scoreboards Prominent visuals showing process performance and other key measures STRUCTURED METHODS Process Mapping A drawing of the workflow showing all steps in a process Standard Work Documented approach (templates, maps, job aids) to ensure consistency A3 Problem Solving Structured tool and process for problem-solving and communication 5S Method for organizing a work area to make it more efficient and orderly Process Walk (Gemba Walk) Walk-through to spot waste and find quick improvement opportunities Six Sigma Statistics-based approach for eliminating defects and variation IMPROVEMENT EVENTS Kaizen Event Structured approach to overhaul a process and plan rollout; 4-5 days Multi-Session PI Event Kaizen event approach but in 2-3 sessions, each lasting 1-3 days Small-Scope PI Event Focuses on a subset process, with rapid rollout; half day to 3 days Value Stream Mapping (VSM) High-level look at processes/systems to find improvement opportunities Lean Process Design Uses Lean concepts to create new processes KEY UNDERLYING CONCEPTS Voice of the Customer Be clear on what creates value from the customer’s perspective Making the Invisible Visible Identify and see all the steps that make up the process Flow Ensure that those value-creating -
Value Stream Mapping to Improve Workplace to Support Lean Environment
MATEC Web of Conferences 135, 00032 (2017) DOI: 10.1051/matecconf/201713500032 ICME’17 Value Stream Mapping to Improve Workplace to support Lean Environment Ahmad Nur Aizat Ahmad.1,*, Te Chuan Lee.1 Rohaizan Ramlan.1 , Md. Fauzi Ahmad. 1, Norafifah Husin 2 and Mustaqqim Abdul Rahim.3 1Department of Production and Operation Management, Faculty of Technology Management and Business, Universiti Tun Hussein Onn Malaysia (UTHM), Malaysia 2Department of Industrial Engineering, Faculty of Mechanical Engineering, Universiti Teknologi Malaysia (UTM), Malaysia 3Department of Civil Engineering, School of Environmental Engineering, Universiti Malaysia Perlis (UniMAP), Malaysia Abstract. In recent years, lean manufacturing is being followed by various sectors in order to keep their competitiveness in the global markets. Lean manufacturing plays a vital role in improving the efficiency of operation by eliminating or reducing wastes. Nonetheless, most of small and medium enterprises (SMEs) lack sufficient knowledge or information on the benefits of implementing lean manufacturing. The main objective of this study is to apply value stream mapping, one of lean manufacturing tools, for improving the productivity in a SME by eliminating non-value added activities. In this study, lean manufacturing was adopted at a SME, particularly a food industry. Value stream mapping was served as main tool to identify the wastes and improvement opportunities in production line. Subsequently, different lean manufacturing tools such as Kaizen Burst, one piece flow, and 5S were applied to eliminate or reduce identified wastes. Based on the future state value stream mapping, final results showed that the total operation time and non-added value activities time were successfully decreased from 1993 seconds to 1719 seconds, and 234 seconds to 104 seconds, respectively. -
Using DMAIC in Improvement of Customer Satisfaction and Facilities Provided at Commuter Stations
International Journal of Academic Research in Business and Social Sciences 2016, Vol. 6, No. 12 ISSN: 2222-6990 Using DMAIC in Improvement of Customer Satisfaction and Facilities provided at Commuter Stations Roslina Mustapha1, Nurul Fadly Habidin2 1Department of Business Management, Faculty of Management and Economics, Universiti Pendidikan Sultan Idris, 35900 Tanjung Malim, Perak, Malaysia 2Department of Management and Leadership, Faculty of Management and Economics, Universiti Pendidikan Sultan Idris, 35900 Tanjong Malim, Perak, Malaysia DOI: 10.6007/IJARBSS/6-i12/2564 URL: http://dx.doi.org/10.6007/IJARBSS/v6-i12/2564 Abstracts This paper discusses the use of six sigma approach to improvement of customer service and facilities at commuter stations. The management of commuter stations should be sensitive to the needs and desires of the passengers. In this study, DMAIC approach taking into accounts the views of the customer (VOC) to the dissatisfaction of commuter services and facilities available at commuter stations. Keywords: Six sigma, DMAIC, customer satisfaction, business management 1. Introduction The performance of a business, whether private or public sector is depends on customer satisfaction. For commuter service almost 20 years of presence in Malaysia, there are still some problems, especially to people with disabilities (PWDs) who want to use the commuter service. Using the six-sigma approach is one way to solve the problem of quality of service. Problem solving is an activity to change what is actually happening to what is supposed to happen (Evans & Lindsay, 2007). People with disabilities are not left behind in the services for commuters as it is one of the convenient public transports, safe and cheap. -
Metrics That Trigger Actionable Discussions: Prioritize Process Improvements Using Gauge R&R and SPC Capability
Metrics That Trigger Actionable Discussions: Prioritize Process Improvements Using Gauge R&R and SPC Capability by Govindarajan (Govind) Ramu If a typical process engineering review meeting at your organization involves engineers staring at scores of presentation slides and feeling overwhelmed, you may want to consider the metrics you’re using. High-level metrics like throughput yield and scrap may seem like logical choices for regular product reviews, and they are useful at a business level; however, they tend not to trigger actionable improvement discussion. In contrast, the same powerful tools that engineers use in their everyday product development and process management applications can have enhanced benefits when put to work for broader decision making about improvements. Integrating tools like failure mode and effects analysis (FMEA), gauge repeatability and reproducibility (GR&R), and statistical process control (SPC) provides a quality improvement framework that organizations can use to monitor process health, prioritize improvements, and assign resources to actions that warrant most attention. Figure 1 shows how FMEA, GR&R, and SPC can be analyzed in the context of relationships between critical to quality (CTQ) and critical to process (CTP) parameters, leading to creation of a “process health card.” In eight steps, you can build your own process health card and begin using it at your engineering review meetings. With your focus strongly on metrics of practical interest to product and process engineers—GR&R results, SPC stability status, and the potential risk to the organization of rejecting good parts or accepting bad parts (misclassification) which impacts the organization’s cost of poor quality—you should find it easier to engage in the actionable discussions that the meeting should foster.