Lean 6S Training

Mercy 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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 1. Wasted Human Talent

I’ve made a few

changes to the
I wish someone process.
would ask OUR
opinion…!

Staff
Manager
Staff
Staff

Staff
Staff

Not asking the staff that works the process how

to improve it 4
 2. Defects

Another
defect!! @*&#!
!

A negative outcome from process failure

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 3. Inventory

Did I really
order this
much??

Items in greater quantities than can be immediately

processed or used. 6
 4. Over Production

I didn’t get my
Hey…are these
order yet… I’ll
multiple orders for the
send another
same thing? @#$&*!!
fax.

Staff
Pharmacist

Generating more work than is really required

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 5. Waiting

People waiting for items (patients, supplies,

specimens, etc.) to process
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 6. Motion
Why can’t I get
anything done?

Unnecessary human movement

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 7. Transportation
Waiting Area

I have orders to
I’ll bring the patient run some tests.
right over.

Sigh…..!!

Unnecessary movement or relocation of items

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 8. Over Processing

Please
approve.

Please
approve.
Please
approve.

Please
approve.
Please
Please
approve.
approve.

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 8. Over Processing

I’m the final

approval. Please
?? The final
approve.
? approval?!!

Applying effort to activities that are not required

in the process
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 What is 6S?

1. Sort
2. Straighten
3. Scrub 6. Safety
4. Standardize
5. Sustain

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 Step 1: Sort
Before After

Separate the needed from the not needed 14

 Step 2: Straighten
BEFORE AFTER

A place for everything & everything in its place!

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 Step 3: Scrub (inspect)

“Scrub” and inspect

equipment to ensure it is
in perfect working
condition...
Add inspecting
equipment into your
work routine.

Regularly “scrub” to ensure everything is in

perfect working condition 16
 Step 4: Standardize

Note: Blue taped outlines and

labels ensure equipment is quickly
found and returned to the same
spot every time.

Standard Work requires determining the best

method then following that method every time.
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 Step 4: Standardize

Note labels and

instructions

Visual Controls ensure that anyone can find what they

need in a matter of moments.
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 Step 5: Sustain

Develop a method for sustaining your gains

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 Step 6: Safety

 Safety first when determining where items

are to be located:
 Keep fire hydrants clear
 Electrical a safe distance from plumbing
 All items accessible - Not too high, not too low
 Uncluttered traffic areas - no tripping hazards
 Emergency phone numbers and procedures
prominently posted

Safety is a top priority in all that you do!20

How do I Conduct a 6S?

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 Preparation
 Observe the process first hand (Gemba
walk)
 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 spent
searching or waiting

Good preparation is the key to successful results!

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 Spaghetti Diagram
Time & Distance Traveled - Before

Supply Chart
Room Rack Printer

100 feet 16 min

Ancillary
Testing 200 feet 16 min
Patient’s 150 feet 11 min
Room
250 feet 11 min

200 feet 1 min

150 feet 31 min
Med
Nurse’s Tube 200 feet 1 min
Room
Station Station
Report 300 feet 21 min
Room
1,550 Feet 108 min

What forms of “Waste” can you identify?

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 How Can We Improve?
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, are
the expert!

Applying 6S eliminates waste!

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 Spaghetti Diagram
No Searching or Waiting - After I’ve found my
“dream” job!

50 feet 1.5 min

Supply
Room Dedicated 50 feet 2 min
Staff 50 feet 1.5 min

50 feet 1.5 min

Med Report
Room Room 50 feet 1 min

50 feet 30 min

Chart Tube Ancillary Patient’s Nurse’s 50 feet 1 min

Rack Station Testing Room Station Printer
50 feet 1.5 min

400 ft 40 min

Reduced travel by 1150 ft & search time by 68 min. 25

 Suggest you insert some before and after
pictures/examples of 6S results in the next
few slides.

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Simulation – Round 1

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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 up
by 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 28
 Instructions to the Class
 Efficiency Expert #1
 Count the number of steps Person #1 travels from beginning to
end 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

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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
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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
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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 working
condition
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

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 Instructions to the Class

 Now that you have identified the waste and the

opportunities 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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