Embed Size (px)
Citation preview
Introduction to Lean Six Sigma –Training & Workshop - Session 4OCTOBER 2, 2015
KITSAP PUBLIC HEALTH DISTRICT
TRAINER: MODINAT OGUN, ASQ CSSBB|CMQ /OE|LSSBB
Training & Workshop Agenda
6/12/2016 2CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Activity Duration
Welcome 2 minutes
Summary of Session 3 20 minutes
Training/Workshop (continued):Lean Six Sigma (LSS) = Define | Measure | Analyze | Improve | Control | Share (DMAICS)Q&A After each phase
10 minutes break after each hour
Quiz 10 minutes
Q&A
Adjourn
Team Norms
Aka Team rules of engagement
Open mind
Share
Fully participate
Collaborative mindset
Learn
Have fun
6/12/2016 3CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Why Should This Matter?
RESOURCES: Ever dwindling and having to do more with less!
6/12/2016 4CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Time
How do you spend 8-10 hour day?Do you have effective & efficient processes?
Funds
Do you have enough funding?
People
Do you have enough & the right people to do the work?
Why Should This Matter?
6/12/2016 5CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
EH Staff: 39
County Population (2014 US Census data): 254,183
Ratio EH Staff to Population: 1 : 6517.5
County size: 566 square miles (Land = 395, Water =
171 (30%) )
Ratio EH Staff to County Size: 1 : 14.5 sq miles
Why Should This Matter?
6/12/2016 6CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Need for a
◦ Mindful,
◦ Thoughtful,
◦ Standardized,
◦ Disciplined,
◦ SME infused approach (versus firefighting) to resource utilization, processes and systems management.
This is where QUALITY comes in…
Overview of Quality & Lean Six Sigma (cont)
In addition, all quality programs share 4 essential quality principles. Quality Principles focus on:
1. Customer Requirements
2. Process Performance
3. Evidence based decision making
4. Continuous & Scientific approach
6/12/2016 7CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Overview of Quality & Lean Six Sigma (cont)
Meaning of Lean Six Sigma (LSS) (belts, project duration)
Lean = is the systematic approach to identifying and eliminating waste through continuous improvement.
Six Sigma = the reduction of defects, focus on problem solving
Combination of 2 powerful methods Process improvement methodology Best way to determine root cause of problems, then fix efficiently &
effectively
6/12/2016 8CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Training – Workshop OverviewLean Six Sigma (LSS) = data-driven improvement cycle used for improving, optimizing and stabilizing business processes and designs. Core tool used to drive Lean Six Sigma projects.
◦ Define
◦ Measure
◦ Analyze = D-M-A-I-C-S◦ Improve
◦ Control
◦ Share
6/12/2016 9CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Training – Workshop Overview
6/12/2016 10CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Lean Six Sigma Definition Chart
Define D The purpose is to define the problem, improvement activity, opportunity for improvement, project goals, customer (internal & external) requirements.
Measure M The heart of what makes Lean Six Sigma work. Observe the process. Gather data. Map the process in depth.
Analyze A Make sense of the information and data collected. Use data to confirm source of delays, waste, poor quality, look for patterns.
Improve I Make recommendations for changes in a process that eliminate defects, waste, costs. Tests, simulations, process mapping
Control C Ensure that improvements to the process are sustained. Documentation, Training of personnel, put measures in place to prevent regressing
Share S Inform all stakeholders via email, meetings, newsletter, website , celebrate, share lessons learned
Measure phase
Definition: process performance.
Tools: Discussed :
Voice of Customer
Trend Charts
Brainstorming
Hands On Workshop: Spaghetti Diagrams (flipchart exercise)
6/12/2016 11CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Lean Concepts8 Types of Waste
•WASTE: Activities that consume resources but add no value
• Visible waste e.g. scrap, rework, downtime, excess
• Invisible waste e.g. wait times of people and machines
Table follows…
6/12/2016 12CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Lean Concepts
6/12/2016 13CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
WASTE DEFINITION EXAMPLES
OverproductionGenerating more information and products than needed
Creating reports no one readsUnnecessary meetings
Transportation
Movement of products and information that does not add value
Retrieving or storing filesCarrying documents to and from shared equipmentMoving parts or assemblies to multiple staging areas before installing
Motion
Movement of people that does not add value Searching for filesClearing away files on the deskGathering informationLooking for tools, parts, and equipment to perform a job
Lean Concepts
6/12/2016 14CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
WASTE DEFINITION EXAMPLES
Waiting
Idle time created when material, information, people or equipment is not ready
Waiting for approvalsWaiting for the system to come back upWaiting for inspectionWaiting for paint or seal to dryCopy machine A handed-off file to come back
Over processing
Doing more than what the customer requires Creating reportsRemoving packaging from partsBreaking down and reassembling equipmentUse of inappropriate software
Inventory
More information and/or material on hand than the end-user needs right now
Files waiting to be worked onOpen projectsJust-in-case inventory anticipatedE-mails waiting to be readUnused records in the database
Defects/Rework
Work that contains errors, rework, mistakes or lacks something necessary
Missing informationProduct carried to the next work station due to late partsLost records
Under-utilization of staff
Losing time, ideas, skills, improvements, and learning opportunities by not engaging or listening to your employees
Professional staff doing administrative workBusy workNot using staff to their fullest potential
Q & A
6/12/2016 15CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Analyze phaseDefinition: Make sense of the information and data collected. Use data to confirm source of delays, waste, poor quality, look for patterns.
Tools:
Discuss:
• Root Cause Analysis aka Fishbone Diagram aka Cause and Effect Diagram (maybe Jessica can teach in detail in Council meeting)
• 5 Whys – briefly discuss w. example (can learn by using in Council meeting for training) (slide)
• Process Map Review (slide)
Hands On Workshop: Pareto Charts | Force Field Analysis (handouts & flipchart execersise)
6/12/2016 16CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Analyze phase
6/12/2016 17CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Because the battery is dead
The alternator is not functioning
The alternator belt is broken
Useful service life of belt exceeded
Belt was never inspected/serviced
WHY?
WHY?
WHY?
WHY?
WHY?
My car will not start
Problem/Issue:
STEP 1
STEP 2
ROOT CAUSE
Process MappingWhat is It?
• Graphic/Visual representation of the ACTUAL flow of people, information, materials
• Illustrated on a floor map diagram
• Finished map looks like “spaghetti”
• Can be used in Define, Measure, Analyze phase
• Purpose:
• Expose inefficient process layouts
• Unnecessary travel distance between process steps
• Overall process waste
• Hands-on exercise (call for volunteers)
6/12/2016 18CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Process Mapping
6/12/2016 19CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Analyze phaseTools:
Hands On Workshop: Pareto Charts | Force Field Analysis (handouts & flipchart exercise)
6/12/2016 20CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Q & A
6/12/2016 21CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Improve phase
Definition: Make recommendations for changes in a process that eliminate defects, waste, costs. Tests, simulations, process mapping.
Tools:
Discuss:
Mistake Proofing -discuss
Standard Work – discuss philosophy
Kanban – how this could apply to government?
Hands On Workshop: Value Stream Mapping (handout review)
6/12/2016 22CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Improve phaseTools: Discuss:
Mistake Proofing = aka error proofing – implementation of fail-safe mechanisms to prevent a process from producing defects.
Standard Work = discuss philosophy –
• one of the most powerful lean tools.
• Document current best practice - forms the baseline for continuous improvement.
• As the standard is improved, the new standard becomes the baseline for further improvements, and so on.
Improving standardized work is a never-ending process!
6/12/2016 23CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Improve phaseTools: Discuss:
Kanban = how this could apply to government?
•Japanese term for one of the primary tools of a just-in-time system.
•Maintains an orderly and efficient flow of materials throughout the entire manufacturing process.
•It is usually a printed card that contains specific information such as part name, description and quantity.
•In organizations, kanban board can be visual management systems of projects (on hold, in process, done)
Hands On Workshop: Value Stream Mapping (handout review)
6/12/2016 24CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Control phase
Definition: Ensure that improvements to the process are sustained. Documentation, Training of personnel, put measures in place to prevent regressing
Tools:
• Training
• Documentation (Operations/Desk Manuals, New Hire Orientation, Protocols)
• Control Plan
6/12/2016 25CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Control phase
Tools:
• Training & Documentation (Operations/Desk Manuals, New Hire Orientation, Protocols)
• Control Plan = Written descriptions of the systems for controlling process quality by addressing the key characteristics such as customer requirements
• Action Plan = a way to ensure that vision is made concrete.
• Standard Operating Procedures = manuals, protocols, procedures, instructions, WAC codes
6/12/2016 26CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Control phase
Tools:
• Control Plan – centralized document to keep track of the status of ALL
significant process characteristics.
6/12/2016 27CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Control Plan – Project Title - Date
Process Feature Action Owner Status (open/closed)
Date Comments/Notes
PerformanceMeasures
IdentifyData/Measurementsource
John Open 9/29/2015 Database is being developed
Share phase
Definition: Inform all stakeholders via email, meetings, newsletter, website , celebrate, share lessons learned. Road show for new tools, processes, procedures, promote training & education.
Tools:
• All Staff / Town Hall Meetings
• Newsletter
• Social Media
• Website
• All Staff Emails
6/12/2016 28CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Share phase
6/12/2016 29CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Q & A
6/12/2016 30CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Final Thoughts
6/12/2016 31CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Personal Motto: “Quality is Why, What, Where, Who and How You Do!”
Collaboration & Cooperation – all hands on deck – problems solving involves collaboration: cool video to helpthat illustrates this… https://www.youtube.com/watch?v=lNaI8j0f7qY
What does this mean?
When Always have a “Quality” mindset
What How are you utilizing your resources?
Who Who is your customer? Internal, External, All Stakeholders, Voice of Customer
How Utilize a mindful, thoughtful, disciplined, standardized approach
Why Ask WHY are we doing this? Why this way? Is there another way? Share & Learn!
Why Should This Matter?
RESOURCES: Ever dwindling and having to do more with less!
6/12/2016 32CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Time
How do you spend 8-10 hour day?Do you have effective & efficient processes?
Funds
Do you have enough funding?
People
Do you have enough & the right people to do the work?
Why Should This Matter?
6/12/2016 33CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
EH Staff: 39
County Population (2014 US Census data): 254,183
Ratio EH Staff to Population: 1 : 6517.5
County size: 566 square miles (Land = 395, Water =
171 (30%) )
Ratio EH Staff to County Size: 1 : 14.5 sq miles
Q & A
6/12/2016 34CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
ClickTEST YOUR KNOWLEDGE
3/11/2015 35
Statement: Waste = Activities that consume resources but add no value!
True or False?
CENTERS FOR EXCELLENCEWWW.PHCFE.ORG
ClickTEST YOUR KNOWLEDGE
3/11/2015 36
What is Lean?
What is Six Sigma?
CENTERS FOR EXCELLENCEWWW.PHCFE.ORG
ClickTEST YOUR KNOWLEDGE
3/11/2015 37
Lean Six Sigma is a…
a) Mindset for solving problems
b) Method for solving problems
c) Toolkit for solving problems
d) All of the above
CENTERS FOR EXCELLENCEWWW.PHCFE.ORG
ClickTEST YOUR KNOWLEDGE
3/11/2015 38
Name the 8 Types of Waste
CENTERS FOR EXCELLENCEWWW.PHCFE.ORG
ClickTEST YOUR KNOWLEDGE
3/11/2015 39
Lean Six Sigma can help you solve problems with…
a) Delays
b) Errors
c) Variation
d) All of the above
CENTERS FOR EXCELLENCEWWW.PHCFE.ORG
Q & A
6/12/2016 40CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
Resources
PHCE Contact:
Cindan Gizzi, MPH
Community Assessment Manager
253-798-7695
41CENTERS FOR EXCELLENCE
WWW.PHCFE.ORG
CSSBB Primer, Quality Council of Indiana, 2012
Bialek, R., Duffy, G.L., Moran, J.W., (2009). The Public Health Quality Improvement Handbook. ASQ Quality Press
iSixSigma: Six Sigma Resources for Six Sigma Quality - Web site: www.isixsigma.com
Kubiak, T., & Benbow, D. (2009). The certified six sigma black belt handbook (2nd ed.). Milwaukee, Wis.: ASQ Quality Press.
Public Health Performance Management Centers for Excellence Web site: www.doh.wa.gov/PHIP/perfmgtcenters
Certified Quality Manager Handbook
ASQ – www.asq.org
Wikipedia - http://www.wikipedia.org/
Moresteam: https://www.moresteam.com/new-to-lean-six-sigma.cfm
SixSigma Training: www.sixsigmatraining.org
Lean Six Sigma Trainer Contact:
Modinat Ogun, ASQ CSSBB, CMQ|OE, CQIA, LSSBB
Quality Management Consultant
253-344-3655
