Many of our customers are at the point in their Lean Six Sigma journeys where it's time to train their staff, often using the Six Sigma belt system to create a special infrastructure of people in the organization who are trained to use Six Sigma quality management methods. Typically, Green Belts are employees who contribute to the organization's Six Sigma implementation in addition to their regular work duties, while Yellow Belts are employees trained in Six Sigma methodology who participate in projects led by Green Belts. Part of the required training for these Belt levels is participation in a Lean Six Sigma project.
Our customers find that KaiNexus is a big help in managing these classes, allowing facilitators to oversee all projects simultaneously and improving the communication and reporting necessary to complete and evaluate each project. Wellstar Health System does an excellent job of managing these Six Sigma classes in KaiNexus, and is seeing significant impacts from their training classes.
Upon completion of the classroom training portion of the Yellow Belt class, students are required to conduct a Lean Waste Walk in which they identify each of Lean’s eight types of waste (defects, over-production, waiting, non-standard processing, transportation, intellect, motion, and excessive inventory). Students must then try to identify two to three examples of each type of waste, followed by brainstorming ways to reduce the wastes or non-value added activities.
Students must then create a Project Charter, to be approved by the course facilitators, that includes:
All documents related each project are attached to the relevant project in KaiNexus, thereby storing all relevant information in a single location and eliminating the need for email and shared file drives. The class facilitators provide feedback on Project Charters in comments entered into the project in KaiNexus.
The 19 students in this class worked on 11 improvement projects, with 100% resulting in an improvement in finances, quality, safety, and/or satisfaction. Here's the breakdown of the impact their opportunities for improvement had:
Excessive Supply Purchases
The purchasing of excessive supplies for a single OR has resulted in $40,000 in waste since Dec. 2013. This includes all non-catalog items (directly ordered from the company) and items that come from the Wellstar Distribution Center.
- Remove unnecessary products
- Review order history
- Get staff opinions on unneeded products
- Modify doctor preference cards
The student implementing this project interviewed staff to determine which products were used and which should not be ordered, and worked with doctors to decide which products to use uniformly. 54 items were removed from the par form
- One-Time Revenue Generation: $23,048 (the price of items removed and credited)
- Saved at least 5-10 minutes for each case pulled, because staff are no longer pulling unnecessary supplies.
- Removed 54 items from the OR par form.