(ARC302) Running Lean Architectures: How to Optimize for Cost Efficiency | AWS re:Invent 2014
The Lean Approach to Optimize and Improve Efficiency Food ......A Certified Lean Six Sigma Black...
Transcript of The Lean Approach to Optimize and Improve Efficiency Food ......A Certified Lean Six Sigma Black...
P I O N E E R I N G D I A G N O S T I C S
FSS - 2019
The Lean Approach to
Optimize and Improve Efficiency
for Pathogen and Quality Indicator Testing in a
Food microbiological laboratory
May, 2019
2
Mohammed T. Ahmed M.Sc., C.Chem (Senior Consultant / Manager Laboratory Optimization)
A Certified Lean Six Sigma Black Belt with an in-depth knowledge of
Microbiology including lab instrumentation and over 15 years of
experience in applying Lean and Six Sigma Methodology in process and
performance improvement.
Area of expertise is lean enterprise and six sigma, Kaizen, Advanced
Statistical techniques (SPC, MSA and DOE), business process
management, business analysis, project management and facilitation
skills.
Mohammed is a Charted Chemist and holds a M.Sc degree in
Chemistry.
Email: [email protected]
Mobile: 905-867-0666
BIOS
6
EFFECTIVENESS & EFFICIENCY
Effective (adj.) – Adequate to accomplish a purpose; producing the intended or expected result.
Efficient (adj.) – Performing or functioning in the best possible manner with the least waste of time and effort.
7
Elements of Time
Value-Adding Activities:Transform products or information into
products and services the customer
wants.
Non-Value-Adding Activities:Consume resources, but don't directly
contribute to process or service.
Value is always defined from the customer’s perspective
8
TIMWOOD – 7 types of waste
Non Value Added Work
Transportation of
Samples
Excess Inventory:
i.e. 1 large batch of
plates
Motion within the
work station.
Waiting for Results
or next processDefects/Re-workOver - ProcessingOver - Production
9
Value Added & Non Value Added Examples
Value Added:1. Sample reception – Logging samples.2. Ordering supplies.3. Sample Preparation.4. Incubation.5. Reading 6. Sending Report to Customer(s).
Non Value Added:1. Waiting2. Moving3. Inspection4. Checking5. Copying and Filing.
10
Making the Lab more Efficient
Value Added ActivitiesNon-value Activity
Lead Time
Efficient companies focus on eliminating non value added activities
to make larger, lasting improvements in lead time
NVAVA
Current State Process
NVAVA
Traditional Focus Of Process Improvement
NVAVA
Focus On Reducing Non Value Added ActivityMinor
Improvement
11
Lean Six Sigma: What does it mean?
The CONTINUOUS IMPROVEMENT OF
QUALITY, ACCURACY AND THE REDUCTION OF
PROBLEMS AND PROCESS VARIABILITY
OPTIMIZATION OF PROCESS WITH REDUCTION OR
ELIMINATION OF TASKS WITHOUT ADDED VALUE AND REDUCTION OF TIME DELAY IN
DELIVERY
COMBINATION OF BOTH METODOLOGIS TO ENSURE THE
BEST RESULTS IN TERMS OF PRODUCTIVITY, QUALITY, COSTS
AND OPTIMIZING PERFORMANCE
The Lean accelerates the Six Sigma: resolution of problems and
improvement of processes to a more rapid and efficient
12
MAIN OBJECTIVES
Improve efficiency and productivity
Operational cost reduction
Quality assurance of products and services Decrease the
Processing time (Turn Around Time)
Increase the capacity of analysis and flexibility for demand
management variables
Process standardization - Workflow Optimization - Improving
Traceability
14
RECEPTION AND SAMPLE INFO RECORDCURRENT SITUATION
7
REGISTRATION OF SAMPLES. INFORMATION ENTRY VERY
MANUAL AND INVOLVES DUPLICATION IN
DOCUMENTATION
1
23
4
56
SIGNIFICANT ADMINISTRATIVE TASK I
15
CULTURE MEDIA PREPARATIONCURRENT SITUATION
CULTURE MEDIA PREPARATION 100%
MANUAL
MANUAL IDENTIFICATION OF TUBES AND PLATES DURING THE CULTURE MEDIA
PREPARATION
MANUAL RECORDS FOR CONTROL OF
CULTURE MEDIA PRODUCED
EXCESS OF MANUAL TRANSCRIPTION
16
SAMPLE PREPARATION | INOCULATIONCURRENT SITUATION
NOT ERGONOMIC LOCALIZATIONOF
SAMPLE BLENDER AND HEARING
INSTRUMENT IMPACT
THE VOLUME OF
DILUENTS ARE
MEASURED MANUALLY IN
THE INOCULATION STEP
MANUAL IDENTIFICATIONOF
PLATES ANDPETRIFILM
UNIFICATION OF PROCESS OFWEIGHING
AND INOCULATION (PRIMARY DILUTION)
INTO A SINGLE STEP BY AUTOMATION
USE OF LABELS FOR THE
IDENTIFICATION OF TUBES AND
PLATES
STANDARIZATION
REDUCTION OF MANUALTASKS
TECHNICAL TIMESAVINGS
PROCESSING TIMESAVINGS
IMPROVEMENT OFTRACEABILITY
REDUCTION OF TRANSCRIPTIONERRORS
STORAGE FOR INOCULATION IN
"BATCH“ PROCESS
17
INCUBATION
CURRENT SITUATION & RECOMMENDATIONS
THERE IS NO
MANAGEMENT OF
INCUBATION TIMES /
READING
MANUAL TEMPERATURES
RECORD OF INCUBATORSAND
REFRIGERATORS
VISUAL MANAGEMENT DATE / TIME INCUBATION /
READING
READINGS OS CULTURES IN APPROPRIATE TIME
AUTOMATION OF THE WAY TO MANAGE THE
TEMPERATURE OF INCUBATORS, AUTOCLAVES
AND REFRIGERATORS
IMPROVEMENT OF QUALITY
IMPROVEMENT OFTRACEABILITY
REDUCTION OF MANUAL TASKS
SOME READINGS
ARE OCCURRING
WITH INCUBATION
18H LESS
19
OBSERVATION ON FOUR(4) ACTIVITY
CATEGORIES
Technical
Processing of samples, Performing productive tasks,
Unpacking sample boxex, Unpacking samples, Loading or
unloading instruments, Looking in Microscope
AdministrativeIdentification, results keyboarding, Typing information on PC
Writing Information. Scanning label, Labeling sample
Transportation Transporting specimens to bench, Transporting plates to
incubators, Transporting reagents to bench.
Movement
Moving items on workplace, Arranging or Sorting plates
Searching in / around workplace.
21
QUALITY INDICATORS ANALISYS
CURRENT X PROPOSED SITUATION |
BIOMÉRIEUX SOLUTION
PROPOSED
TAT
(DAYS)
1,00
1,00
1,00
1,00
1,00
1,00
3,00
PARAMETER OFANALISYS
CURRENT TAT (DAYS)
AVERAGE MEDIAN 3º QUARTIL
AERÓBIOS MESÓFILOS 3,60 3,00 4,00
ENTEROBACTERIACEAE 3,41 3,00 4,00
COLIFORMES TOTAIS 4,11 3,00 5,00
ESCHERICHIACOLI 4,03 3,00 5,00
STAPHYLOCOCCUS 3,98 3,00 5,00
BACILLUSCEREUS 4,43 4,00 5,00
BOLORES ELEVEDURAS 6,11 6,00 7,00
TAT
REDUCTION
(DAYS)
-3,00
-3,00
-4,00
-4,00
-4,00
-4,00
-4,00
FASTERRESULTS
REDUCTION IN UP TO 4 DAYS THE RELEASETIME
(*) Global TAT –Considering only the analysis times. Not considering the processing timevariations
TAT – CURRENT x PROPOSED
22
QUALITY INDICATORS ANALISYS
CURRENT X PROPOSED SITUATION |
BIOMÉRIEUX SOLUTION
Preparation of Media
1
Dilution
3Inoculation
42
Sample Preparation
Fill
5
Incubation6
Reading7 Release of
Results
8
WORKFLOW – TRADITIONAL METHOD x TEMPO
REMOVED STEPS WITH AUTOMATION
24
Classifying activities
• Aligning staffing with workload• Read multiple
batches• Cross training
Do more
•Multiple Touches•Holding results•Over-processing
Stop doing
• Add new procedures & technologies
• Balance Cost/Quality/TAT
Keep doing
25
Lessons Learned
Management buy-in is “CRITICAL” for change
Continuous Improvement Mind-set, Go & See (Gemba)
Just DO IT (kaizen)
Respect for People
Thank You for Attention
Contact:
Mohammed T. Ahmed, M.Sc., C.Chem.
Certified Lean-Six Sigma Black Belt.
Consultant / Manager, Laboratory Optimization
Mobile: 905-867-0666
Email: [email protected]