Lean Six Sigma Case Study 2023
Acme Laboratories is a specialised facility that tests samples sent in from a wide range of sources – hospitals, forensic science departments etc.
There are typically seven different sample types, each having to undergo one or more tests.
Workload
Product A accounted for 60% of the workload.
Product B accounted for 19% of the workload.
Product C accounted for 11% of the workload.
Products D,E, F and G accounted for 4%, 3%, 2% and 1% of the workload respectively.
Testing
Products A and C were from the same product family and received the same testing procedures, requiring nine different tests.
Products B,D, E, F and G only required two simple tests.
Cycle Times
Data regarding cycle times for different products were available and, as an example, the cycle time data for product A during a period from January to April were:
14 samples in 0-5 days, 148 samples in 6-10 days, 239 samples in 11-15 days, 82 samples in 16-20 days, 48 samples in 21-25 days, 25 samples in 26-30 days, 50 samples in 30+ days.
The present target cycle time was 15 days
Workflow
Each day, the lab received between 1 and 17 samples
Each week the lab received between 25 and 45 samples.
Once tested, the results had to pass through a lengthy approval process and also a release procedure before completion.
There was on-going pressure from the customers to speed up the turnaround time without compromising the accuracy and traceability of the testing process.
Objective
Imagine using Lean Six Sigma methodology, describe how improvements might have been made.
Describe the tools that might have been used in this quality improvement process, their purpose and when they were used.
Use a minimum of three Lean Six Sigma tools in each of the DMAIC phases.
Chart some of the data that might have been gleaned during the project.
How should the goal of the project be chosen?
Write a suitable project scope, problem statement, business case, CTQ etc.
Use your team to brainstorm possible areas for improvement, and create an Ishakawa diagram forthe project.
Document a possible solution to the improvement project.
Emphasise the before and after metrics which clearly identify the savings in KPI’s such as time or quality and ultimately the financial savings from the project.
Not more than 3,000 words.
For citations, use the Harvard referencing system
Sample Solution
Lean Six Sigma Methodology The Lean Six Sigma methodology has five distinct phases: Define, Measure, Analyse, Improve and Control. Each of these phases requires different tools and approaches to ensure the success of the project
Define - The first step in the process is to define the problem. In this case, Acme Laboratories was under pressure from customers to speed up their turnaround time without compromising accuracy or traceability of testing processes. The team should begin by creating a Project Charter that outlines the purpose, resources and objectives of the project. Next they should create a Problem Statement which defines what needs to be improved and how it will benefit Acme Laboratories. This can then be converted into a Business Case which shows how much money could potentially be saved by implementing improvements. Finally a CTQ (Critical To Quality) Tree should be created detailing all key elements necessary for successful completion of the project. Tools such as Ishikawa Diagrams can also help identify root causes for further investigation in later stages of DMAIC methodology..
Measure - Data must then be gathered on current processes so that areas for improvement can be identified more effectively. This stage involves using tools like SIPOC (Supplier-Input-Process-Output-Customer), Pareto Charts and Histograms to capture data around cycle times and products tested during specific periods over time etc., allowing teams to determine an exact baseline measure before any changes are made within workflow processes or staff training is implemented etc.. Metrics such as Time/Cycle Time comparisons between different products may also need recording here too, enabling teams form an accurate picture ahead fo moveing forward with possible solutions at later stages..
Analyse - Once enough data is collected it's important to analyse it carefully before deciding on possible solutions.. Tools like Brainstorming sessions through fishbone diagrams or 5 Why's are useful when exploring root causes behind problems at hand since each tool encourages continued drilling down until true cause(s) are discoverd rather than just settling for obvious symptoms only... For example, Ishikawa diagrams allow teams break down parts od entire system in order o better understand input/output relationships between them while Paretos may highlight areas needing most attention based on frequency percentage percentages associated with each problem area & thereby providing focus upon those particular sections only within total workflow rather than trying fix everything simultaneously....
Improve - Now that awareness has been raised around issues needing addressing within Acme Laboratories’s sample testing facility its time start looking real possibilities offering best chance increase efficiency decrease turnround times without sacrificing quality service being provided by Labs… Possible solutions include ideas related anything from Equipment Automation & Reduction Waste or Streamlining Staff Training Processes & Validation checks right through onto Providing Appropriate Resources needed complete tasks efficiently well developing Standard Operating Procedures clarify roles responsibilities beyond…. By applying various Toolkits such Kaizen Yamzaki Empowerment every part process wille nsure optimised end results generated next phase Control….
Control – After improvements have been put place teams must monitor track their progress ensure ongoing benefits derived from effort time invested previous four steps… Utilising techniques both Statistical Process Control & Controls Charts sets benchmark targets sustained performance maintained throughout whole system ..By tracking metrics such Cycle Times Cost Savings customer satisfaction levels etc over course period usually six months year desired level expected results eventually achieved….. Furthermore Threshold alarm points set wake everyone concerned certain thresholds exceeded alert corrective action taken immediately safeguard against future potential breakdowns.....