MPC’s National Roadmap for · PDF fileMPC’s National Roadmap for LEAN 1 LEAN...

KandunganMPC’s National Roadmap for LEAN 1LEAN Healthcare Hub Centre – State of Kelantan 2Creanova LEAN 2014 3Kuantan Specialist Hospital Sdn Bhd (KSH) 4Kaizen Self Skill Report 5LEAN Healthcare in KPJ Tawakkal Specialist Hospital Operation Theatre 6ESS Kiosk Rapid Bas 7Memoir En. Massimo di Annual Productivity and Innovation Conference (APIC) di Bukit Gambang City Resort 2013 8LEAN HoW – Walk The Talk 9LEAN Quiz 10Exciting Programmes In June-Sept 2014! 11Sekretariat LEAN 12

Issue 4January-April,

2014Malaysia Productivity Corporation (MPC)(Centre of Excellence for LEAN)

LEAN management originates from Toyota Production System (TPS), which is developed by Toyota Motor Corporation. It is a management philosophy that

shortens the time between customer order and products/services delivered by eliminating wastes (Taiichi Ohno).

Malaysia Productivity Corporation (MPC) has introduced the MPC’s LEAN Roadmap. It is a systematic approach to promote LEAN management that complements the existing quality and productivity initiatives, thus integrating all efforts

competitiveness of the nation.

The LEAN thinking is the backdrop of the roadmap. It is driven by kaizen activities, which are embedded in the LEAN thinking. The LEAN thinking can be adapted as an organisation culture in the quest for organisational excellence.

MPC’s National Roadmap for LEAN

The wide range of LEAN management activities is introduced. LEAN Hands-on- Workshop and LEAN international study mission are designed to expose LEAN

practitioners to best practices implemented by the best organisations. The TRIZ Centre

of Excellence has been set up in MPC Northern Region.

The public sector special projects on LEAN management are launched with the collaboration of various State Secretary

management at the Federal Government level starts with an awareness seminar

organised by lead government agencies.

The Creanova LEAN is a best practices sharing session for

selected organisations. 15 top LEAN management projects were shared

during this session.

The LEAN Healthcare leads towards LEAN Enterprise. A patient normally has to go through various departments to receive treatments,

thus the project improvement’s collective efforts carried out in

these departments will contribute to customer satisfaction. The LEAN

Healthcare projects are done with the collaboration of Ministry

of Health.

The formation of LEAN culture within an organisation is the ultimate goal.

They are able to recognise and eliminate wastes in their processes.

MPC will recognise a practising individual as a LEAN Champion and an organisation as a LEAN practising

company.

MPC will recognise their efforts and give them the opportunity to present

their achievement in LEAN summit, or other similar sharing session.

The Centre of Excellence for LEAN management has been set up at MPC

Wilayah Pantai Timur. It is to coordinate all LEAN management promotion efforts and activities. A series of Round Table Discussion was organised to get buy-in from experts as well as implementers.

The LEAN management pilot projects, which used Enterprise Innovation

Intervention Program (EIIP) approach, were launched. The intervention

programme was carried out within 6 months.

The LEAN management awareness seminar was organised within this period. It was a sequel

to “What next after 5S”. It was

organisations which already have the system installed for more than

3 years.

It provides a strong footing with broad-based Knowledge Management. Over the years,

MPC has been offering technical and management knowledge in

quality and productivity, in the form of training programmes, seminar,

publication and others.

YBhg. Dato’ Mohd. Razali Hussain

LEAN Empowers Leadership

LEAN Healthcare Hub Centre – State of Kelantan

COMPLETED PROJECTS

ONGOING PROJECTS

Putrajaya

Kulim

Penang

Johor Bahru

Ipoh

HRPZ II

KPJ PAKAR PERDANA

KBMC

Pusat Kesihatan Pergigian

Ideal Healthcare

HUSM

Hospital Sultanah Aminah- UniKL project

MPC Petaling Jaya- LEAN Healthcare Committee

MPC EAST COAST REGIONAL OFFICE- CoE LEAN

LEAN HEALTHCARE HUB – MPC KELANTAN OFFICE

Kuching

Kota Kinabalu

MPC Kelantan Office

Direction of Communications

KPJ Kuantan Specialist

POTENTIAL 5 private hospitals from KPJ

Group Other hospitals/clinics at

Regional Offices

*Information Based on MPC Healthcare Roadmap Petaling Jaya – Presented at Rtd LEAN Healthcare on 24/3/14

ON-GOING PROJECTS

KPJ PAKAR PERDANA

126 beds Services – A&E, Diagnostics and

Imaging Services, Patient Services, Medical Records and pharmacy

LEAN projects Outpatient Treatment Time Cash Payer Waiting Time GL Patient Waiting Time Medical Supply to Ward

KOTA BHARU MEDICAL CENTRE

44 beds LEAN Projects (unconfirmed)

HOSP RAJA PEREMPUAN ZAINAB II

920 beds LEAN Projects (unconfirmed)

HOSP.USM

800 beds Services – Laboratory, pharmacy,

Patient Services, Medical reports and Clinical Support services

LEAN Projects Outpatient at KRK clinic ESWL Patient at operation theatre Medical supply to ward Rehabilitation product supply Dental case by student (to be reviewed)

Perbadanan Produktiviti Malaysia, MPC telah melakar satu lagi sejarah dalam kalendar aktiviti tahunan kerana telah berjaya menganjurkan CREANOVA LEAN pada

27 Februari, 2014 di Bukit Gambang Resort City, Kuantan, Pahang.

Program yang bertemakan ‘Aspirasi Peneraju Kecemerlangan Organisasi’ ini telah dirasmikan oleh Yang Berhormat

Ismail dengan 15 organisasi mempersembahkan projek masing-masing yang terdiri daripada:

Creanova LEAN 2014 yang julung kali diadakan ini telah menarik perhatian seramai 359 pemerhati daripada 89 organisasi yang terdiri daripada sektor awam dan juga swasta untuk hadir bagi melihat sendiri perkongsian maklumat dan amalan terbaik Pengurusan LEAN yang dilakukan oleh 13 Kumpulan Projek yang terpilih.

Creanova LEAN 2014

LEAN 2014.

YBhg. Dato’ Sri Muhammad

LEAN MPC.

LEAN 2014.


Kuantan Specialist Hospital Sdn Bhd (KSH)Tajuk projek ‘Missing Gauze During Surgery’ oleh Kuantan Specialist Hospital Sdn Bhd (KSH) telah dinobat sebagai Anugerah Projek Terbaik Creanova LEAN 2014 di Bukit Gambang Resort City Kuantan. Projek ini telah berjaya menyelesaikan isu masa mengira gauze sediaada sebelum pembedahan dan selepas pembedahan adalah sama/kekal 10 keping.

Kumpulan KSH telah menggunakan kaedah Pemetaan Proses (Value Stream Mapping) dan Poka Yoke sebagai idea penambahbaikan kecekapan proses kerja semasa.

Pelaksanaan Pengurusan LEAN KSH ini telah mendapat kesan langsung atau impak yang sangat baik iaitu dengan berlakunya pengurangan masa mengira jumlah gauze daripada 60 saat (1 minit) kepada 10 saat, tidak berlaku kesalahan dalam pengiraan dan tidak perlu melakukan ulangan pengiraan terhadap gauze yang telah digunakan atau belum digunakan.

Kumpulan telah mencipta dulang/tray untuk letak gauze yang di namakan VIGO (Visual Gauze Organiser) dan alat indicator untuk abdominal pad yang dinamakan APIP (Abdominal Pad Indicator Plate). Kedua-dua inovasi ini telah membantu masalah pengiraan gauze semasa pembedahan dan mempercepatkan tempoh masa pengiraan.

Impak dari projek ini mengurangkan masa pengiraan untuk 10 gauze dari 10 saat kepada 1 saat sahaja dan menghalang dari berlaku kesilapan pengiraan. Pengiraan secara berulang juga tidak perlu dilakukan kerana gauze akan diletak dalam dulang yang dipantau melalui VIGO. Impak yang paling besar adalah tidak berlaku kesilapan tertinggal gauze semasa pembedahan.

Pemenang Anugerah Projek Terbaik Creanova LEAN 2014 Kuantan Specialist Hospital Sdn Bhd.

Tray VIGO ( Visual

Gauze Organizer )

yang memastikan

bilangan Gauze

selepas dan sebelum

pembedahan adalah

sama.



The project is started by 3 Kaizen Members in Integrated Capillary Tube (IC Tube) Department. The Kaizen Members are Mr. Mohd. Haniff, Mr. Amirudin Ismail and

its team leader, Mr. Suhairi. The objective of this project is to improve Machine Process Cycle Time by Reduce Non Value Added (NVA) Activities. This Kaizen Blitz Project takes 5 working days to be completed. Initially, Value Stream Mapping (VSM) is being mapped out in order to identify its Kaizen Blitz spot. GEMBA activity and details data is collected and used for spotting and identifying its NVA Activities along the processes. Results found from studying the data show that Drawing Process Element consumes 37.1s from the total 83.1s. It takes

up 45% of the total process time. By further analysis of this Drawing Process Element, it is found that 55% of the time is taken by NVA activity. So, Brainstorming session is carried out

in order to ensure that the root cause of the problem is precisely

together in order to achieve the target set. After all the actions are completed, the following has been achieved: Production Lead Time and Cycle Time are reduced to 5.62% and 13.3% respectively. The very important lesson learnt by members is to always train our eyes to have power to identify wastes so as to

Kaizen Self Skill ReportKobelco & Materials Copper Tube (M) Sdn Bhd

LEAN Healthcare in KPJ Tawakkal Specialist Hospital Operation TheatreMain Author: Hannah Fong , M.EdCo-Author: Parakkal Sumita A/P C. Kochukrishanan, B.Sc (Pharm) Hons.

Introduction: KPJTSH has adopted LEAN tools and principles, throughout every engagement of surgical patient from admission until surgery. It was used to focus on increasing staff satisfaction level, improve standard work, process visibility and effective communication to ensure schedule cases are on time, to reduce leakage for consumable items and redundancy of work, to reduce time in pre-operation preparation of patient; reduce rework and increase carnation ward process

sof Itnd se ee s

Objectives: 1. To improve OT standard work processes. 2. To remove the non-value added activities (8 wastes).

Methodologies: KPJTSH has built LEAN principles in our hospital QIA programme based on a concept of engaging the skills and knowledge through:

Results: : Staff and Surgeons satisfaction rate

increase from 20% to 85%Quality Right : Rate of accomplishment of trolleys

First Time from 30% to 100%

Cost : Increase of OT Utilisation increase :

Time mins to 20 mins



ESS Kiosk Rapid BasEmployee Self Service (ESS) Kiosk adalah mesin elektronik yang digunakan oleh kakitangan terutama kapten bas untuk mengeluarkan waybill digital dan untuk rujukan Jabatan Sumber Manusia. Mesin ini mengurangkan penggunaan kertas, tenaga kerja dan mengurangkan kos pembayaran kerja lebih masa seperti dalam laporan yang disertakan berbanding penggunaan proses manual sebelum ini.

Sebelum ESS dilaksanakan, kaedah manual sij dijalankan adalah seperti berikut :-

1. Kapten bas dikehendaki beratur untuk mendapatkan Waybill Pemandu (Panjang barisan bergantung kepada jumlah Kapten Bas di Depoh Tertentu).

2. Fleet Co-ordinator (FC) yang bertugas hanya 1 orang atau 2 orang sahaja setiap hari.

3. Untuk mendapatkan waybill, Kapten bas perlu mengambil masa lebih kurang 6 minit seorang dengan menggunakan kaedah ini.

4. Tugas Fleet Co-ordinator (FC) pula perlu menulis nama, laluan, nombor pendaftaran bas dan tarikh untuk setiap seorang Kapten bas yang membuat laporan.

5. Kapten bas perlu mengisi borang cuti secara manual dan menunggu untuk diluluskan.

Selepas penggunaan ESS Kiosk1. Kapten bas dikehendaki beratur untuk mengeluarkan waybill pemandu melalui KIOSK.

2. Setiap Depoh diperuntukkan 3 atau lebih KIOSK

(bergantung kepada saiz Depoh).3. Untuk mendaptkan waybill, Kapten Bas hanya mengambil masa kurang daripada 1 minit seorang.

4. Tanpa penggunaan Tenaga Manusia yang maksima

yang mana di waybill tersebut telah tertulis semua

maklumat yang diperlukan.5. Sekiranya Kapten bas ingin memohon cuti, mereka

hanya perlu mengisi borang secara atas talian di

KIOSK dan menunggu beberapa minit sahaja untuk

mendapat maklum balas samada diluluskan atau

tidak.

6. Semakan gaji juga boleh dibuat terus di KIOSK

tanpa menunggu penyata gaji dari bahagian gaji.Impak dari Projek ESS Kiosk

Majlis Pelancaran 5S di RapidKL Depoh Bas Shah Alam.

Memoir En. Massimo di Annual Productivity and Innovation Conference (APIC) di Bukit Gambang City Resort 2013

En Massimo menikmati juadah tradisional nasi lemak bersama YBhg. Dato’ Haji Ahmad Fadzil Mahmud dan En. Nik Mustafa Raja Salleh di Taman Esplanade, Kuantan, Pahang.

Sesi Perkongsian pengalaman En Massimo bersama organisasi di Perbadanan Kemajuan Negeri Pahang (PKNP), Kuantan, Pahang.


En. Massimo Appioti daripada Valeocon Management Consulting adalah pakar LEAN dan Six Sigma mempunyai 15 tahun pengalaman dalam

kecemerlangan operasi dan tranformasi perniagaan di banyak organisasi di seluruh dunia. Antara program LEAN yang dilaksanakan adalah seperti di General Electric Capital, Alstom, Novartis, J&J, BNP Paribas, Société Générale dan Whirlpool.

Semasa APIC 2013 beliau telah membentang kertas kerja bertajuk System Customer Centricity the New Frontier of Service Excellence and LEAN Management. Kertas kerja ini membincangkan nilai dan rantaian pelaggan dalam memberi perkhidmatan dan anjakan paradigma dalam organisasi semasa memberi perkhidmatan yang memenuhi keperluan pelanggan.

Melalui jalinan kerjasama ini, En.Massimo pakar LEAN jemputan antarabangsa turut berkongsi ilmu dan pengalaman di Perbadanan Kemajuan Negeri Pahang (PKNP) dengan kertas kerja yang bertajuk LEAN Implementation in Service Sector. Sesi perkongsian ini telah dihadiri oleh beberapa organisasi Negeri Pahang antaranya Majlis Perbandaran Kuantan, Pejabat Tanah, Daerah Kuantan dan lain-lain. Dalam sesi ini juga, beliau bersetuju dengan kaedah membangunkan pelaksanaan Pengurusan LEAN di PKNP dan mengkagumi impak yang diperolehi oleh organisasi ini dengan beberapa projek Pengurusan LEAN yang sedang dilaksanakan.

Di Universiti Teknologi Malaysia (UiTM) Pahang, Kampus Jengka beliau membentangkan kertas kerja bertajuk LEAN in Education. Dalam pembentangan ini, beliau berkongsi bagaimana pengurusan LEAN membantu meningkat kecekapan sistem pendidikan. Sesi ini juga telah dihadiri oleh Pengurusan UiTM Pahang, Pensyarah-Pensyarah dan pelajar UiTM.

Selain daripada tugas-tugas rasmi beliau, memoir bersama En Massimo yang tidak akan dilupa dan menjadi kenangan pihak MPC ialah beliau seorang yang mudah mesra dan sikap ingin mencuba makanan Melayu semasa berada di Malaysia. Kenangan indah bersama yang tidak dapat dilupa yang buat kami tersenyum, apabila beliau kepedasan mencuba hidangan nasi lemak dan mencuba hidangan nasi berlauk ikan patin masak tempoyak menggunakan tangan walaupun menikmati hidangan tersebut menggunakan hanya 3 jari. Terima kasih En. Massimo.

Kenangan En. Massimo bersama-sama dengan Pegawai-pegawai Kanan UiTM. Berdiri dari kanan (No. 3) ialah YBhg Prof Madya Dato’ Dr Haji Hilmi Bin Ab Rahman, Rektor UiTM Pahang (sekarang ini Rektor UiTM Kelantan).

T

Presentation by En. Nik Mustafa Raja Salleh.

Opening remarks by YBhg. Dato’ Ir. Noor Azmi b. Hj. Jaafar - Managing Director of Delloyd Industries.

Explanation by Hjh. Nor Aini Talib for the MPC’s Passage Way Tour.

Group photo of the delegates together with the senior management of Delloyd.

YBhg. Dato’ Hj. Ahmad Fadzil Mahmud pining the LEAN Badge Award on YBhg. Dato’ Ir. Noor Azmi.

LEAN HoW – Walk The Talk 1. They use Value Stream Mapping to:

2. They identify the non-value added activity to 151.5 minutes processing time, while the value added is only 1.5 minutes.

3. They use Yokoten – the Japanese methods in continuos improvement activities, such as 5S, Suggestion scheme & QCC project.

4. They identify 11 types of wastes in their organisation (instead of 8 types of wastes). The other 3 wastes are:

5. The LEAN Tools they have been using include:

PbMR

YBhg Dato’ Hj Ahmad Fadzil Mahmud pining

E l ti b Hjh N Ai i T lib f th MPC’

Group photo of the delegates together with the senior management of Delloyd.



LEAN QUIZPlease complete the crossword puzzle below:

Name:__________________________________________________________

NRIC No:________________________________________________________

Tel:___________________ Email:____________________________________

Address:________________________________________________________

________________________________________________________________

Postcode: _______________ State:_________________ City:______________

PERADUAN KUIZ just LEAN,Malaysia Productivity Corporation(MPC),Lorong Produktiviti, Off Jalan Sultan,P.O. Box 64, 46904 Petaling Jaya(Att: Azira Mohamed Hodzai)

or fax to 603-7955 1824 (Attn: Azira Mohamed Hodzai)or visit http: for online entry.

1. A four-step cycle of Continuous Improvement (Kaizen)2. Error3. Overburden4. Five phases of LEAN Six-Sigma Methodology

1. The fourth principle in LEAN Thinking.5. ________ work is one of LEAN tools.6. Last good part of one product run to the rst good part

of the next product run.7. Unnecessary raw materials, goods, or

work-in-progress.

1. This contest is open to all Malaysians except MPC staff.

2. Contestants can submit as many entries as they wish but only one is

uali ed to win.3. inners will be noti ed by email or

phone call.4. MPC has the right to change the prize

without any noti cation.5. Closing date: 30th June, 2014.

6

7

5

1

2

3

4


Exciting Programmes In June-Sept 2014!REGION DATES VENUE CO-ORDINATOR

LEAN Asia Summit 17-18 Sept Petaling Jaya Md. Shubri Ismail/ Hanisah Mohd. Ramli

PROGRAMME DATES VENUE FEES (RM) CO-ORDINATORLEAN Management – Visual Factory & Operational Measurement

6-7 May Petaling Jaya 1,000

LEAN Management – Standardised Work 21-22 May Petaling Jaya 1,000 Semawi Zakaria

LEAN Management – Value Stream Mapping (VSM) 10-11 June Kota Kinabalu 1,000 Edward Binty

LEAN Management – Total Productive Maintenance 10-11 June Petaling Jaya 1,000 Hanisah Mohd Ramli

Business Process Reengineering 24-25 Sept Petaling Jaya 1,000 Saliza Saari

REGION DATES VENUE FEES (RM) CO-ORDINATOR

Northern 30 Apr Pulau Pinang 500 Josffa Ismail/ Norazlina Tun Ibrahim

Central 5 June Petaling Jaya 500 Azira Mohamed Hodzai

Southern 18 June Johor 500 Zul Ezwan/ Noor Mohd Farhan

East Coast 26 Aug Terengganu 500 Muhaslizawati Mohd Bakri

Southern 18 June Johor 500 Zul Ezwan/ Noor Mohd Farhan

COUNTRY DATES ASSOCIATION CO-ORDINATOR

Indonesia 15-20 June Wahana Kendali Mutu Norazlina Tun Ibrahim /Noor Mohamad Farhan

Germany 22-27 June LEAN Institute ® Germany Saliza Saari

Taiwan 23-27 June China Corporation Centre (CPC) Rosmi Abdullah/ Cham Yin Hwa


Sekretariat LEAN

Ketua PengarahYBhg. Dato’ Mohd. Razali Hussain,

Ketua Pengarah,Perbadanan Produktiviti Malaysia (MPC)

Timbalan Ketua Pengarah IYBhg. Dato’ Hj. Ahmad Fadzil Mahmud,

Timbalan Ketua Pengarah I

PengarahNik Mustafa Raja Salleh

[email protected]

Nordieana Nordin (PA)

Pengurus Kanan Hjh. Nor Aini Ab. Talib

[email protected]

PengurusMd. Shubri [email protected]

Rosmi [email protected]

Pegawai Perunding KananSaliza [email protected]

Pegawai PerundingNorhasimah IbrahimMohd Hilmi Mohd Idris

Norazlina Tun IbrahimHanisah Mohd RamliCham Yin Hwa (Penyelaras)Noor Mohamad Farhan Noor AzmanAzira Mohd HodzaiMohd Faizol Abd RahmanWan Nur Hidiatul Akmal Wan Juslee

TerbitanSekretariat LEAN,Bahagian Inovasi Enterpris (EI)Perbadanan Produktiviti Malaysia (MPC)y ( )

Ucapan Terima Kasih Khas Kepada Penulis Luaran

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