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Lean 6S TrainingMercy Medical Center
5046 LDLEAN6S - Version 8/20/2009
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What are the 8 Forms of Waste?
What is 6S?
How do I conduct a 6S?
Examples of Mercy 6S results
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8 Forms of Waste
1. WASTED HUMAN TALENT
2. DEFECTS
3. INVENTORY
4. OVERPRODUCTION
5. WAITING TIME
6. MOTION
7. TRANSPORTATION
8. PROCESSING WASTE
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Not asking the staff that works the process how
to improve it
1. Wasted Human Talent
I’ve made a few
changes to the
process.
Staff
Staff
Staff
Manager
I wish someone
would ask OUR
opinion…!
Staff
Staff
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@*&#!
!
A negative outcome from process failure
2. Defects
Another
defect!!
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Items in greater quantities than can be immediately
processed or used.
3. Inventory
Did I really
order this
much??
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Generating more work than is really required
4. Over Production
Staff
Hey…are these
multiple orders for the
same thing? @#$&*!!
I didn’t get my
order yet… I’ll
send another
fax.
Pharmacist
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People waiting for items (patients, supplies,
specimens, etc.) to process
5. Waiting
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Unnecessary human movement
6. MotionWhy can’t I get
anything done?
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Unnecessary movement or relocation of items
7. Transportation
I have orders to
run some tests.I’ll bring the patient
right over.
Waiting Area
Sigh…..!!
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8. Over Processing
Please
approve.
Please
approve.
Please
approve.
Please
approve.
Please
approve.
Please
approve.
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8. Over Processing
I’m the finalapproval.The final
approval?!!
Applying effort to activities that are not required
in the process
Please
approve.
+
??
?
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1. Sort
2. Straighten
3. Scrub
4. Standardize
5. Sustain
What is 6S?
6. Safety
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Step 1: Sort
Separate the needed from the not needed
BeforeAfter
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Step 2: Straighten
A place for everything & everything in its place!
BEFORE AFTER
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Step 3: Scrub (inspect)
Regularly “scrub” to ensure everything is in
perfect working condition
“Scrub” and inspectequipment to ensure it is
in perfect working
condition...
Add inspecting
equipment into your
work routine.
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Step 4: Standardize
Standard Work requires determining the best
method then following that method every time.
Note: Blue taped outlines and
labels ensure equipment is quickly
found and returned to the same
spot every time.
St 4 St d di
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Visual Controls ensure that anyone can find what they
need in a matter of moments.
Note labels andinstructions
Step 4: Standardize
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Step 5: Sustain
Develop a method for sustaining your gains
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How do I Conduct a 6S?
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Preparation
Observe the process first hand (Gembawalk)
Create a spaghetti diagram - a hand
drawn map of your process including: Tasks in the sequence they are done
Location of supplies and equipment
Measure distance traveled and time spentsearching or waiting
Good preparation is the key to successful results!
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23What forms of “Waste” can you identify?
Ancillary
Testing
Supply
RoomChartRack
TubeStation
Printer
Patient’s
Room
Nurse’s
Station
Med
RoomReportRoom
200 feet
100 feet
150 feet
250 feet
200 feet
150 feet
200 feet300 feet
1,550 Feet
Time & Distance Traveled - Before
Spaghetti Diagram
108 min
16 min
16 min
11 min
21 min
11 min
1 min
31 min
1 min
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What would you do to improve?
Sort out the need from the not needed
Have a place for everything so there is no searching
Move supplies or equipment closer to where they are
needed
Co-locate tasks or people
Change the sequence in which tasks are done
Be creative with your solutions – you, after all, arethe expert!
How Can We Improve?
Applying 6S eliminates waste!
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Spaghetti Diagram
No Searching or Waiting - After
Reduced travel by 1150 ft & search time by 68 min.
Chart
Rack
Ancillary
Testing Printer
Tube
Station
Nurse’s
Station
Patient’s
Room
MedRoom
SupplyRoom
ReportRoom
Dedicated
Staff
I’ve found my“dream” job!
40 min
1.5 min
2 min
1.5 min
1.5 min
1.5 min
1 min
30 min
1 min
400 ft
50 feet
50 feet
50 feet
50 feet
50 feet
50 feet
50 feet
50 feet
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Simulation – Round 1
I t ti t th Cl
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Instructions to the Class
Worker
Gather White, Yellow and Blue sheets of paper Paper clip the sheets together
Place in a folder
Place post-it on the outside of the folder
Place folder and contents on the chair (to be picked upby a delivery person)
Manager
Create a spaghetti diagram: Draw the room layout, identifying the location of the
supplies used in the simulation
As Participant #1 walks the process, trace his/her
footsteps on the spaghetti diagram
I t ti t th Cl
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Instructions to the Class
Efficiency Expert #1
Count the number of steps Person #1 travels from beginning toend in the process.
Efficiency Expert #2 Track how much time Participant #1 takes to do the entire
process
Track how much time is wasted waiting and/or searching
Customer Do a quality inspection on the finished product against the
sample provided to you by the Instructor
Co-workers (Rest of Class) Identify the 8 Forms of Waste in our process
Identify possible ideas for improvement
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Quantifying the Results
Capture the Results from Round 1
Wh t A th R lt ?
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What Are the Results? Manager
What does the spaghetti diagram show us?
Efficiency Expert #1 How many steps did it take for the worker to do the process?
Efficiency Expert #2
How much time did the entire process take? How much time was wasted waiting and/or searching?
Customer Was the customer happy with the service provided (quality
inspection)?
Rest of Class Identify forms of waste in the process
Include possible ideas for improvement
Wh t W t Did Y Ob ?
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What Waste Did You Observe?
1. Wasted Human Talent
2. Defects
3. Inventory
4. Over Producing
5. Waiting
6. Motion
7. Transportation
8. Over Processing
H C W U 6S t I ?
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How Can We Use 6S to Improve?
1. Sort – Separate the needed from the not needed
2. Straighten – A place for everything and
everything in its place
3. Scrub – Ensure everything is in perfect workingcondition
4. Standardize – Determine the best method –
visual queues, labeling, etc.
5. Sustain – Develop Standard Work
6. Safety – Safety first at all times
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Simulation – Round 2
Instr ctions to the Class
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Instructions to the Class
Now that you have identified the waste and theopportunities for improvement in the process
Put your recommended improvements in place
We’ll run the simulation a second time
Then we’ll measure the results…
….and celebrate our success!!
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Quantifying the Results
Capture the Results from Round 2
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