Sponsored by the book "Lean Hospitals" | Free Download of First Chapter


Monday, June 30, 2008

LeanBoard Jobs Area

Some of you know that I have a modest "message board" site at www.leanboard.org. I've retooled it a bit to focus on Lean Healthcare issues when my book is available. I've always had a free job postings board and activity has taken off lately. Some representative positions: These postings and your ability to view them are always free. Contact info for different jobs can be found within the posts. The Danaher position seems like it would be an exciting chance to be a part of one of the top Lean companies out there, other than Toyota. My former manager, when I was at Honeywell, was a former Fluke/Danaher guy and he was very impressive in his Lean background and philosophy (hey Mike, if you're reading this!!)
Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board

Labels: ,

"Factory" - A New Situation "Comedy"

Full Episode: Premiere Episode - SPIKE I saw an ad for this the other day, I don't really have high expectations prior to watching it. Will a sitcom set in a factory be as clever as "The Office" or even "Gung Ho" or will it be full of blue-collar beer-swilling stereotypes? You can watch the episode online and judge for yourself. Be warned, it's a bit raunchy, if that bothers you. Unfunny bothers me more than raunchy. My notes from as I watched:
  • Opening scene: It's pretty rare to see CNC machines on TV. That's cool, I guess. Whoa, that's disturbing, seeing a manager/supervisor/engineer pulled into the machine by his tie - not overly graphic, compared to CSI.... but this is how the comedy begins? Anything that reinforces the "no ties around machines" message is OK, I guess.... but not the funniest thing ever. Maybe this is why TV shows aren't set in factories?
  • OK, halfway through the show now... still not too much humor. So I'll comment on it as if it's not a comedy. After the guy is killed, the big boss needs to replace him. He decides to have the main four characters of the show "vote" to decide who gets the job. I hope that sets up some comedy, since that's a pretty stupid way to go.
Final verdict -- it's more a show about a bunch of guys than a show about a factory... and not very funny. Can't recommend it.
Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board

Labels:

Ultimate Factories -- Fire Trucks

I was watching a show (via Tivo, back over the weekend) that I just discovered on the National Geographic Channel -- Ultimate Factories, their episode on fire truck manufacturing at Pierce Manufacturing. It's a cool show for HD also. I think the "Ultimate" in the title tends to refer to the size of the products, not the Lean-ness or manufacturing excellence, necessarily. Episodes focus on products like John Deere farming gear and Winnebagos.

It takes 45 days to build a fire truck - each one is basically custom. But, of course, there's no mention of how much of that 45 days elapsed time is "Value Adding" -- and how much is waste. We'll see as the show progresses.
"There are 33,000 fire departments and they each put out fires differently. So we have to be flexible in our design," says the company president.
Are there really that many ways to put fires out? I can imagine having complete customization of features like paint color (they have 100+ versions of red -- this isn't Henry Ford!!) or graphics but I"m surprised there's THAT much product customization. Building fire trucks seems more like building airplanes - where an airline can specify just about anything they want (or is that changing nowadays)?

The fabrication department has laser cutters that don't just crank out hundreds of the same part over and over (building inventory). They take three days worth of orders and software optimizes what parts will be cut out of which sheets -- all of the parts needed to make the suspension. So although suspensions are built in batches, off line from the primary assembly area, the fabrication process does its best to minimize wasted sheet steel. Three days at a time -- does anyone have any context for how that compares to other similar manufacturers?

The factory layout (as shown by the show) is pretty functional - fabrication, painting, final assembly. The fabrication area is pretty far from final assembly -- it's definitely not a "feeder line" concept. Lots of forklifts and overhead lifts moving things around.

One example of waste reduction -- they use 23 karat gold leaf paper to help put graphics onto the trucks. Pieces that aren't needed are swept up. A supervisor explained that they got $11,000 for the last bags worth of scrap gold leaf paper that they sold back.

Conpared to the other shows like this, the show features interviews with employees and supervisors (like the John Ratzenberger show and unlike the "How It's Made" show that just features a narrator and views of automation). This show focuses on the employees and customer needs, not just whiz-band automation, so I like that. A good amount of this show is focused on design features, not just how it's built, but that's interesting too.



Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board

Labels:

Sunday, June 29, 2008

Jamie Flinchbaugh Video: Daily Improvement

Everybody Everyday: Managing for Daily Improvement

The link above is an online video presentation by Jamie, courtesy of IndustryWeek (click here to subscribe to their print edition of the magazine).

In This Presentation You Will See
  • How 90% of Lean strategies start and end (in minute 10)
  • What you really want (and get) out of 5S (in minute 23)
  • How you measure Lean (in minute 25)
  • The leading metric of truly sustainable Lean change (in minute 27)
  • Using lean to change the work of leaders (in minute 32)
  • How to manage, not just lead (in minute 35)
  • How to integrate Lean into the organization (in minute 41)
  • How to know when problems occur (in minute 44)
  • and more
Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board

Labels: , , , ,

Saturday, June 28, 2008

Blog Format Change - Comments

Hi - if you're a regular reader (or especially a frequent commenter), you may notice a change to how comments are entered.If you click on "comments" to add a comment, this is now done on the main blog page, instead of being in a pop up window.

I'm not sure if I like this approach yet... to read existing comments, you have to scroll up on the page.

What do you think? Should I leave it this way or change it back? I know, I know, I should switch to WordPress.... someone is bound to leave that comment... that's not something I can tackle right now.

Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board

Labels:

Surgical Checklists in the News!

WHO Proposes Checklist to Reduce Surgery Errors : NPR

A surgical revolution: checklist that could prevent thousands of deaths

Thanks to long-time readers Chet and Andrew for pointing out these similar stories, one from NPR in the U.S. and one from The Independent newspaper in the U.K. (front-page news!)

As a Lean thinker, I love the idea of checklists. They are the Lean concept of "standardized work" in a different wrapper. Standardized work helps ensure quality and consistency of processes - whether in a factory, an airplane cockpit, or a medical setting.

Checklists, when done properly, are written by the people who do the work (just as we would do with standardized work). This isn't about consultants, mangers, or a single expert dictating the process to others.

Checklists aren't intended to "turn people into robots." Checklists and standardized work are a foundation, they cover typical situations, but can't cover everything. When a truly unique situation comes up, people are expected to utilize their professional judgment - to use their brains. There's a Toyota expression that says standardized work allows you to avoid hundreds of little decisions so you can make the one major decision that matters.

Checklists aren't "carved in stone" practices that can never change. As new evidence or practices emerge, checklists and standardized work can be improved - that's the Lean concept of "kaizen."

All of these principles were seen back in the story of the cardiac surgeons at Geisinger Health System in Pennsylvania. The surgeons themselves credited the checklists and standardized process for elective bypass surgeries - before, during, and after. The surgeons were able to deviate from the standardized work IF they had a reason they could justify to their peers (not just "because I didn't want to follow it today"). They improved upon their standard over time... and outcomes for patients improved dramatically.

As I've also written about, the work of Dr. Peter Pronovost and Dr. Atul Gawande has proven that checklists are incredibly powerful - preventing infections another preventable patient harm. This probably should be a surprise to Lean thinkers.

So now the World Health Organization is looking to spread these simple, yet powerful, practices around the world.

From NPR:

Since the 1930s, airplane pilots have run through checklists before taking off. Now the World Health Organization wants surgeons all over the globe to use them, too.

Dr. E. Patchen Dellinger, a surgeon at the University of Washington Medical Center in Seattle, says people are surprised when he tells them about the project.

"One of the common reactions is, 'You mean you weren't doing that before? Good heavens!'" he says.

Yes, I can understand that reaction! For all of the medical and clinical brilliance in our hospitals, they often have a great deal of opportunity for operational improvements.

Of course there will be resistance to this - as with any change. Again, from NPR:

Gawande says there's been some resistance to the list. One London surgeon thought it was demeaning "Mickey Mouse stuff" until one day in the operating room.

"Right before the incision [the medical team] took a timeout," Gawande says, "and when it came to the nurse's turn to raise any concerns, the nurse asked: 'Are we really sure we have the right size knee replacement for this patient?'"

Turns out, they didn't — not anywhere in the hospital. That surgeon now swears by the surgical checklist.

The surgeon now sees the benefit of the checklists - to the patient and to themselves (avoiding a lawsuit -- although I don't know how the legal system treats that in the U.K., compared to here in the U.S.). We have to sell people on the benefits of checklists -- not just forcing the method on them and saying "here, do this." It's one of my truisms that "people don't like to be told what to do." That's true not only for doctors... but for practically any time of person or role.

From The Independent:

More than eight million operations were carried out in the UK last year, equivalent to one for every eight people in the population, and there were 129,000 reported incidents in which patients were put at risk, according to the National Patient Safety Agency.

An estimated 2,000 NHS patients die each year as a result of errors in treatment, and an inquiry by the National Audit Office in 2005 concluded that half of all incidents could have been avoided if staff had learnt the lessons of previous mistakes.

And more quotes from Gawande:

Atul Gawande, the US surgeon and columnist for the New Yorker who is leading the initiative for the World Health Organisation, said: "The complexity of medicine has increased to the point where no one person can ensure it is delivered reliably and accurately. We have been struggling for a tool that can help people reliably deliver safe care. The checklist is turning out to be as important to successful care as the stethoscope. I think you could make the case that it is the biggest innovation since the stethoscope."

...

Dr Gawande said: "At the start of the pilot in the eight hospitals, 64 per cent of patients missed at least one check. Putting in the checklist cut the failure rate by half and has reduced deaths and complications, though it is too early to put a figure on it. The remarkable thing was we couldn't tell the first world countries from the developing world countries. This has shown we can do something we have never seen before – improve the safety of surgery on a population basis."

I'm surprised that the error rate was only cut in half. Having the checklist is one thing -- we need a management system and culture that ensures that the checklist is used the right way. Zero errors needs to be the goal with checklists.
Worldwide, the WHO aims to have the checklist operating in 2,500 hospitals in the most populous countries (with 75 per cent of the world's population) by the end of next year.
If you're reading this and you're not a hospital employee or leader -- if you're a patient -- it's time to push your local community hospitals to implement this proven method. If not before YOUR surgery, then before the surgery of a neighbor or a loved one. As Pronovost said before, the only thing stopping us from spreading the use of checklists is a lack of desire to do so.

The method is cheap, it's relatively easy, and it works!

Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board

Labels: , ,

Thursday, June 26, 2008

Tom Peters on Healthcare

From Modern Healthcare, Tom Peters throws a few verbal bombs at the healthcare industry:


Quality gains needn’t be costly, Peters tells HFMA

Financial executives can do more to improve healthcare quality and it won’t cost more money to do so, said management guru Tom Peters, speaking at the Healthcare Financial Management Association’s yearly meeting.

In a keynote speech, Peters told attendees of the gathering that “despite our good work in some areas, like patient safety, we still haven’t reached up to the awful level.” The high number of hospital-caused drug errors and infections is a “disgrace,” Peters said.

Peters is absolutely right that better quality CAN cost less - and it should. Improving processes saves money -- Lean is one way to get there. I guess Peters has earned the right to throw rocks... is it helpful? In his talk, Peters said we need to train more in "people skills" not in numbers. To me, Lean definitely falls into the "people" side as opposed to being really mathematically rigorous like, say, Six Sigma.

Managing the right process will bring the right results -- that Lean truism certainly holds in healthcare. Managing processes means getting out there and seeing how work is done, working with and coaching people. I think the path to improvement can't rely exclusively on measurement, quotas, and incentives. You have to manage the people and the process. I'm hoping Peters would agree with that.

The HFMA website also has an interview with Peters.

Peters often speaks in terms that might remind you of Lean:

My revolution is a revolution of simplicity that gets us focused back on delivering health care and realizing that a lot of our operational problems that are involved with healthcare delivery itself are problems that can be fixed with some straightforward solutions. Just throwing money at these problems is not the answer.

You could think of Lean as a "revolution of simplicity" (he *is* good with turning a phrase). With Lean, we simplify procedures to get the waste out of people's day -- eliminating unnecessary steps and activities so people can focus on caring for patients. That's the brilliance of Lean -- not "working harder" or "being more careful." Lean solutions are straightforward - they seem like common sense, in hindsight -- but yet we're not always adopting these ideas on our own, without Lean training and coaching.

Part of his advice for CFO's:

I don’t want you to sign off on a $3.5 million investment to make patient safety things happen in your hospital. I do want you to sign off on 14 little experiments that go after bits and pieces of it where we can see what works and what doesn’t work.

That's also Lean thinking!! Great stuff from Peters...


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: ,

My Letter to the IE Magazine

I'm a proud member of the Institute of Industrial Engineers and their sub-organization the Society for Health Systems. I try to contribute to the cause with my "Everyday Lean" blog series that they host on their site. I wrote a "letter to editor" after reading something in their magazine recently...

I don't have the exact article I'm referring to from their March edition, but it was a short article (probably pulled from a wire service - a version of it can be found here) about hospitals using information systems and how that benefits patients. I think IE only published the first two paragraphs or so.

Anyway, after reading the article, I wrote a letter (in two separate graphic files, click for a larger view if needed):




I offered to write something (they edited that out of the letter and didn't respond to the offer). It would be nice to see an article in there about what Industrial Engineers are doing with Lean and process improvement activities. I'll have to follow up with one of their editors.


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels:

Wednesday, June 25, 2008

Lean Applications in New Biofuels Production

By Jason Turgeon:

It seems that with oil nearing $140 a barrel, everyone is suddenly excited about improving efficiencies across the board in the world of transportation and fuels. Applying Lean to a process, whether it's the manufacturing of cars or the method of refining fuel used to run those cars, is the best way to find new efficiencies. Of course, any Lean efficiency in energy use or transport that reduces fossil fuel use has an immediate Green payoff, too.

On the subject of Lean, Green, and fossil fuels, this article from the always excellent Cleantech.com describes a very lean-sounding new process for growing biofuels. There's been no shortage of press releases from startups touting breakthroughs in the biofuels arena, especially those interested in producing biodiesel from algae. Lean applications help this latest announcement from the stealthy Algenol Biofuels stand out from the crowd, although the fact that the company already has an $850 million project in the works to bring the product to market doesn't hurt either.

Most algal biofuel companies have focused on growing strains of algae that produce fats as a byproduct of their growth. The fats are then refined into biodiesels which can be used in diesel-fueled engines or as a heating oil. It's a promising arena, but the process generally requires tremendous amounts of fresh water, open space, and sunlight. Open space and sunlight are easy to find -- just go to the desert. But finding fresh water in the desert is a bit of a challenge, and even if you can get the water you have to transport the fuel from the desert to your customer base somewhere else.

Algenol took a look at the process and decided it made more sense to use seawater for its growing medium. There are plenty of deserts that border on oceans, including the Sonora desert in Mexico where its first facility is planned. Another advantage of locating a facility on the coast is that the transport of the fuel to market is easily accomplished by using the existing tanker fleet, a much more efficient method than using trucks. By making the switch from fresh water to seawater, the company has found a way to rid itself of a relatively expensive and scarce input (fresh water) while at the same time shortening its supply chain. That seems very Lean to me.

But the big Lean standout is that instead of refining fats into biodiesel, the Algenol process has used naturally occurring algae that turn the sugars they're fed directly into ethanol, with no refining step needed. Since the Leanness of this move might not be apparent to everyone at first glance, I'll use some phrases from the Lean Manufacturing Glossary to explain myself--I'm not trying to drop buzzwords, just trying to phrase this in a way the Lean audience can understand.

If you were to value-stream map the entire manufacturing process of any fuel, whether it was biofuel or fossil fuel, you would see a large step in the middle called "refining." Until now, refining fuel has been absolutely unavoidable--you can't burn crude oil in your car or feed algae-based lipids directly to your truck's diesel engine. Any Lean improvements to the process would probably look at how to improve the refining process. But Algenol has taken a higher-level view. In a sort of a large-scale Kaizen exercise, the company has found a way to eliminate the refining step. What was once an essential but expensive part of the manufacturing process is now just so much Muda. I'd imagine that for a lot of people in the world of oil, eliminating the refinery is a big paradigm shift.

Here we have an example of a company that seems to have taken a Kaizen approach from the very beginning. The company looked at what it was trying to produce - biofuels - and eliminated as many unnecessary steps as it could. Compared to the process of corn or cellulosic based ethanol, which is shockingly inefficient, it appears that they've succeeded. Compared to other algal biofuels, they've switched a scarce resource - fresh water - for an abundant one -sea water - while eliminating the refining step and minimizing the supply chain expenses. From a waste-reduction standpoint, it looks like they've found a beneficial reuse for the majority of their process wastes. The only outputs seem to be ethanol, fresh water, and the nitrogen-rich dead cell bodies, which can be used to replace fossil-fuel based nitrogen fertilizers. And of course, by taking waste CO2 from other companies, they're closing an important loop and setting themselves up for financial gain if the CO2 trading market finally becomes a reality.

All of this isn't to say there aren't some important questions that haven't been answered. Off the top of my head, I'd like to know what the source of sugars that they are feeding these algae are. I'd also like to know the circumstances surrounding their Mexican land acquisition. The company claims that this is an unused desert wasteland, but that's rarely the case, as the desert has tremendous ecological value and there are almost certainly people who may be displaced to worry about. Finally, I'd like to know more about the real energy balance, since they are awfully shy on details. I note that the process involves a small power plant, but the feedstock for this power plant isn't clear. Will it be running of the ethanol they're producing? But these questions and others aside, I'll remain cautiously optimistic and congratulate the company for coming up with a Lean and Green approach to tackling some of our most pressing problems.


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: , ,

Everyday Lean: Aluminum Foil

snopes.com: Aluminum Foil Locking Tabs

Here's an interesting example of "Everyday Lean" that I never knew about. Have you ever been frustrated by pulling on a roll of aluminum foil (or plastic wrap) and having the roll pop out of the container?

The boxes for these are actually designed with a little method for keeping the roll in the box - a physical method is more effective than "being careful."

Click on the link above for some further explanation and a few photos. It's not rocket science - that's why I love this example. This is designed into the product, but we can use this to think about opportunities to error proof our processes - at work, not just in our kitchens at home.

Does saying "be careful" really work? If this were a workplace and the roll popping out of the box were a serious problem, would we post signs, cautions, and exhortations for our employees, or would we error proof it?


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: ,

Tuesday, June 24, 2008

Nice Quote

Heard a great comment today:

"Suggestions are things somebody else should do. Ideas are things that I can do."


Maybe that is why Norman Bodek's books and the others (The Idea Generator: Quick and Easy Kaizen and Ideas Are Free: How the Idea Revolution Is Liberating People and Transforming Organizations) use that word instead of "suggestion"


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board

Labels: ,

TWI at Energizer Battery

IndustryWeek : Introducing Training Within Industry

Our friend Bryan Lund is featured in this interview with IndustryWeek (click here to subscribe) about the Training Within Industry Program.

I love the focus on developing people:

IW: What do you hope to gain from implementing TWI?

Lund: Confident, problem solving people.

IW: Would you consider this a culture change for your employees? And if yes, how have you been addressing this?

Lund: Absolutely. We see people confident in proceeding with improvements. We see managers more engaged with their people. They are working together to solve problems and aim to standardize them until they find a better way.

We do not go into our sessions looking to change the culture within two weeks as if it were a project. Changing behavior takes time. All we can do is teach some critical skills, coach those people and encourage them to practice those skills every day.

Developing people -- for one, it shows "respect for people" (as Toyota says) and it leads to results for customers and the company. How do people solve problems? How do managers and leaders work with people? That's what it really all comes down to...

I really appreciate all that Bryan has done to help spread the word about the resurgence of the TWI approach. Check out his TWI Blog here.

Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: , ,

Monday, June 23, 2008

Laughable Customer "Service"

I know this falls squarely into the "must be a nice life if this is what you have to complain about" category, but I'll share this anyway.

As I prepared to go to the UK for work for 17 days, I had a car service lined up so I could avoid (my company could avoid) paying for 17 days of parking -- the car service would be cheaper. At the scheduled time, the car had not arrived, which was troubling since a car service normally shows up 15 minutes early.

I called and got a dispatcher who said the driver (pictured at left, artist rendition) was "10 minutes away." 15 minutes later, no car, so I called back. The dispatcher (in New Jersey) had trouble communicating where the car was and there was no way for me to talk directly to the driver. It finally became clear that the car was still 30 minutes away... so I bailed and drove myself to the airport.

My travel agent followed up after I called to complain -- the car service wouldn't charge me for the trip. Ya think? That's the bare minimum -- they really should be on the hook for the parking charges.

I was willing to let it all go, but I got an "apology" letter in the mail.

It reads, in part:

"I understand that weather conditions, holiday traffic, and massive airport delays made a difficult dispatching schedule and we were extremely delayed in picking you up, which forced you to take a cab."

Holy Schnikes, what a laundry list of excuses! The weather was perfect that day. June 2 isn't exactly a huge holiday in the U.S., and I don't think there were "massive airport delays." And while a cab would have been a cost savings, if I had time to wait for a cab, I would have waited for the car service!!!

So, the final comedy -- as these letters tend to go....

"... we take pride in our high quality, on time service.... I offer no excuses, just an apology."

No excuses except all of them in paragraph one of the letter!!!!

It's amazing that a company like this is still in business. Yes, a driver is bound to be late once in a while, but the poorly thought-out response is even more troubling. I did try contacting the rep, as invited, and haven't gotten a call back. Oh, this is "Operator of the Year" as awarded by some industry magazine, their letterhead points out. Yikes!!


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels:

LeanBlog Podcast #47 - Norman Bodek

Norman Bodek is once again back for episode #47 of the LeanBlog Podcast, talking about his most recent trip to Japan (his 68th trip!). He poses the question, "What can we do to leapfrog Toyota?" Norman asks important questions about how we can help people, in any role, enjoy their work, rather than dreading Mondays. Why does Norman think the Canon photocopier plant he just toured is the best he's ever seen? Why does Norman disagree with the phrase, "Work smarter, not harder"??

For earlier episodes, visit the main Podcast page, which includes information on how to subscribe via RSS or via Apple iTunes.

You can use the player (use the VCR-type controls) below to listen to a "streaming" version of the podcast (or click here for the streaming audio and RSS subscription). The streaming link is faster for one-time listening (hardly any delay to start listening). Or you can use the download link to put it on your iPod or other MP3 player.





MP3 File Right-Click to "Save As"

Enhanced AAC File


Episode #47 Key Words and Links:

If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast.


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: ,

Saturday, June 21, 2008

Lean Hospitals Book Survey -- Do You Have a Name for Lean?

As I was researching and writing my book, I conducted an online survey (non-scientific) about hospitals and their experiences with Lean methods. I am going to be sharing some of the summary results, as well as some specific responses (keeping the respondents' information confidential).

If you took my survey and signed up for the mailing list for my book, you'll receive a full summary of the survey responses, or stay tuned here. I'll be publishing small bits and pieces over the next couple of months.

Question #4 from the survey:

Do you have a hospital wide name for your Lean efforts (such as “Hospital Name Production System”)? If so, what is it?

Right about 50% of respondents said “No.” The free form responses included:

  • Patient Flow Project, Administrative Project is not yet named
  • SPPI - System for Productivity and Performance Improvement (pronounced like "spy")
  • Process Improvement
  • Process Improvement
  • Operational Excellence
  • Lean
  • Quality Plus
  • The [University] Quality System
  • Performance Improvement or Performance Excellence
  • Process Excellence
  • Vision 20012
  • [Health System Name] Performance Excellence System
  • Lean Resource Center
  • Building Better Care
  • Just 'Lean Six Sigma'
  • [Hospital Name] Production System
  • Business Process Improvement
  • Customer Value Improvement Process

In my experiences with hospitals, many wish to put “their own stamp” on the approach, creating a sense of something that is being created within the hospital rather than something that is being adapted from the outside.

At the same time, organizations need to be able to share some amount of common language and appreciation of common methods that are used across hospitals. In some cases, the word “Lean” is used within the hospital’s process improvement leaders, but the term is not used widely with hospital staff.

There is often fear of connotations that the word “Lean” might bring. Lean sometimes seems to imply “cuts” -- in budgets or people -- although Lean thinkers would realize these are not the goals of a true Lean implementation.

I think there are no blanket correct answers to this general question -- do we call this “Lean” or do we call it something else in our hospital? It's typical for a hospital to develop a name, such as ThedaCare Improvement System or Virginia Mason Production System, once Lean has taken hold at more than a departmental level.

What are your thoughts on this, either for hospitals or in other industries? Feel free to add your comments here on this post.


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels:

Friday, June 20, 2008

Reader Question: Difficult People

Fire people who think they're entitled to run things - Jacksonville Business Journal:

The linked article and question were sent by a reader who asked, in part:
I discovered your blog and podcast a few months ago and have been following closely. I work in a company recently acquired by a company that's a few years into their lean journey and the parent company has been rolling Lean out in our business unit. I was selected for the implementation team, so I read and listen to everything about Lean that I can get my hands on. Yours is one of my primary resources.

I came across this article and its an issue we've been dealing with and it made me wonder how the "fix" would be handled in the Lean world. Is it something you could blog about?

I'm traveling back home today, so I'll leave the blog in your hands... what are your thoughts on this, from a change management perspective?

From the article:

Imagine you're a newly appointed project leader of an existing management team. How do you know if you're walking into a club of entrenched buddies who want to run the show and will sabotage your efforts? And what can you do about it?

I recently observed a team of a dozen managers with that dynamic. Harry was the newly appointed project leader. His two predecessors, also experienced leaders, had been unable to move the team forward. Both reported problems building team agreement and developing aligned effort.

Sitting in on a team meeting, I saw two people repeatedly cast furtive glances to a third, who signaled displeasure by frowning, eye rolling and head shaking. After each instance, the trio resisted the direction being taken by the rest of the group.

A little investigation on my part revealed the pattern. One person was the queen bee, supported by her attentive court. She thought she should run the whole team because she knew best.

Though she hadn't been able to convince her superiors, she knew the project was going in the wrong direction. In her mind, even worse than her lack of power, was the lack of appreciation to which she felt entitled. Since she knew what was right, she also felt justified in sabotaging everyone else's efforts.

All three of the managers sabotaging Harry were entrenched in the organization. They covered each other's backs. Anyone who disagreed or challenged them with facts was stabbed in the back.

Do you ever see similar patterns in your attempts to help an organization change, or in implementing Lean? What strategies do you use? I'm not sure if there's a "Lean answer" as much as there is a "working with people" answer -- your thoughts??


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board



Labels:

Thursday, June 19, 2008

Let the Process Experts Decide

Leading article: Infected by political calculation

This isn't a "Lean" story, per se, but it still caught my eye. Hospital-acquired infections are a major problem throughout the world. As this commentary from The Independent points out:
Britain has the worst record of hospital infections in Europe, and patient surveys reveal that superbugs have overtaken waiting times as their prime source of concern. The situation could not go unchallenged.
Fair enough -- it's a serious problem and it demands attention. The "solution" reminded me a of a recent rant from a specialist physician I saw back in the U.S. a month ago or so. He started complaining about all of the government interference in healthcare and he said "Every time there's legislation about medicine, they make it worse. They need to let doctors make the decisions, not the politicians."

To be a cynic, a politician's job is to get re-elected. Are they always making decisions that are right for the community or for patients? Back to the article, where the Prime Minister got involved:
But as so often with this administration, new rules have been accompanied with a heavy dose of politically-motivated and unhelpful meddling. Last September, Gordon Brown announced that the 1,500 NHS hospitals in England would be subjected to a "deep clean". It sounded good. This would involve clearing wards, washing walls and scrubbing behind radiators.

But there was a problem. There was no clinical evidence to suggest this was where effort ought to be directed. According to infection control experts, superbugs were being spread not by bacteria multiplying in neglected corners of wards, but by sloppy daily cleaning procedures and the failure of many medical staff to wash their hands properly. Yet the Prime Minister ploughed on anyway because the idea of a deep clean was deemed a way of communicating to the typical voter how seriously he was taking the problem of superbug infections. Most hospitals finished their deep clean three months ago and, as we can see from these latest figures, it has made very little difference to the standards of cleanliness in our wards.

Millions are being spent on efforts that "sound good" or "feel good" instead of doing what really works. Pretty lousy, huh? How do we get local hospitals to manage their "Standardized Work?" -- That's the challenge. It's not a great revelation that hand hygiene is critical. How do we get people to follow good daily processes (for hand hygiene and room/equipment cleaning) instead of taking big splashy efforts that might not make a difference. Did the politicians ASK hospitals, executives or physicians, how to solve this problem or did they mandate a "solution?" Sounds like they should have done more asking.

The column concluded:

This is a lesson on how little is achieved and how much is wasted when politicians put the chase for favourable headlines above expert advice. It is not only our hospitals that urgently need to clean up their act.


Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: , , ,

Wednesday, June 18, 2008

Video Clip -- Mike Micklewright as Dr. Deming

You might remember my podcast with Mike Micklewright, "What Would Deming Say?"

Here is a free video clip of his "An Evening with Dr. Deming" presentation. You can buy the full DVD by clicking here.





Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: ,

These Wounded Soldiers Need Lean To Get Their Benefits?

Soldiers risk ruin while awaiting benefit checks - Yahoo! News

I've read about this problem before... and at the risk of this turning too political, I'm going to address the issue. Wounded U.S. soldiers are reportedly waiting too long to get the benefits to which they're entitled. In the case of one soldier:

Stevens' descent from Army private first-class, 3rd Infantry Division, 11 Bravo Company, began in 2005 — not in battle, since he was never sent off to Iraq or Afghanistan, but with a headfirst fall over a wall on the obstacle course at Fort Benning, Ga. He suffered a head injury and spinal damage.

The injury alone didn't put him in a homeless shelter. Instead, it was military bureaucracy — specifically, the way injured soldiers are discharged on just a fraction of their salary and then forced to wait six to nine months, and sometimes even more than a year, before their full disability payments begin to flow.

That's shameful, injured vets living in homeless shelters.
Nearly 20,000 disabled soldiers were discharged in the past two fiscal years, and lawmakers, veterans' advocates and others say thousands could be facing financial ruin while they wait for their claims to be processed and their benefits to come through.
It sounds like they need a serious dose of Lean thinking. If they're "waiting" for claims to be processed, I can only guess that the "process" is plagued by:
  • Departmental silos
  • Long delays between steps in the process
  • Long delays before decisions or approvals are done as a batch
  • Poor processes that lead to missing information or missing paperwork
I'm speculating and, call me a cynic, I wouldn't be surprised if any of that is the case. I wonder how long it really takes to perform what you might call the "Value Added" steps in this process, which might include:
  • Receive paperwork
  • Verify status
  • Finalize paperwork
  • Start sending checks
If it takes SIX MONTHS to get this done, I bet most of that time is waiting and delay. The U.S. government needs to do better than that. Use Lean thinking, create value streams that are focused on flow (and quality) of focusing on departments, efficiency, and internal politics or battles. Focus on the "customer" of the process - the wounded soldiers. Come on, get it done. I read about this months ago.... let's get this process fixed. For shame...

The point, with this or any Lean improvements, wouldn't be "doing things faster" or cutting corners. One should be able to take significant time out of the process without being sloppy and giving benefits, for example, to just anyone who applied. Reducing delays before verification steps, rather than eliminating such safeguards, would be the "Lean" approach.

Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: ,

Tuesday, June 17, 2008

Lean and Deming's Anti-Slogan Views

Earlier leanblog.org post and comment

Last week, I posted about Deming's 14 points and I got an interesting question from a blog reader, Brian:

I found # 10 confounding: "Eliminate slogans, exhortations and targets."

Slogans are sometimes used to communicate change. While they are just a tiny ingredient in a large recipe for communicating change, they can be effective.

We use targets in our Lean improvement workshops so the team can measure their success at the end of the week.

Is Deming really for eliminating these or am I not understanding his intent? Are some of our Lean practices in opposition to his principles?

Here is my take on it, based on my experience and study of Dr. Deming's teachings. First thought is that when I visited NUMMI in 2005, I saw a lot of large banners with slogans, including their annual Quality Slogan. I thought this was surprising, considering the influence Deming had on Toyota, but someone explained that slogans are OK as long as they aren't "empty slogans." I would never put up signs during a hospital Lean project that exhort people, "Quality is YOUR responsibility." No, it's management's responsibility. We have to improve systems, not exhort people.

I agree that slogans and sayings can be helpful. One team I'm working with now has really embraced the expression, "Don't let best get in the way of better." We don't have it on signs all over the place. Is it a slogan? I guess. Is it bad, I don't think so, since the expression encourages them to take a PDCA approach, try something and see how it works, rather than obsessing over a perfect solution.

Now for targets... my take is that targets and measures for improvement are a good thing. I consider them "goals" more than "targets" and I think there's more to that than the choice of words.

For example, in a project, we expect to improve testing Turnaround Time from XX hours to XX minutes, based on analysis of the process and knowing how much waste there is. Tracking the improvement goals isn't a bad thing. What would be bad is setting an absolute "you must hit this or be punished" target for a project team or staff. Setting quotas such as "you must draw blood from 10 patients per hour, or else" would be a very bad thing, something that Dr. Deming railed against.

What we're trying to avoid is the old "Management by Objectives" sins of managers just hitting targets and then waiting to see the results. We need managers involved in managing and improving the process, not just hitting targets that are often unrealistic. If you set quotas or targets and threaten punishment (or lack of reward) then people will distort the data or they will distort the system - something we really want to avoid.

I hope that helps. What are YOUR perspectives on the use of slogans and targets? I hope we can agree that exhortations are bad, right?

Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: ,

Monday, June 16, 2008

The USPS Should Error Proof This

Express Mail: USPS Says Guaranteed Overnight Isn't Guaranteed. What?

Saw this post on The Consumerist blog about how the United States Postal Service does NOT guarantee overnight delivery of "guaranteed" overnight documents.... IF you place the package in a drop box instead of handing it to an agent at the counter.

What?

According to the blog report:
Dorothy found out that the USPS's guaranteed overnight delivery doesn't apply if you use their Express Mail boxes, because "Letters get stuck up in the top of the box all the time. Sometimes, it takes days or even a week before we find them." Hey post office, maybe you should try to check the top of the box every day. Problem solved!
Checking the box every day would be a form of inspection -- that's waste.

It would be better if the USPS could design a drop box that prevents letters from getting stuck. It's called "error proofing" (or "poka yoke" if you insist on the Japanese term). It's not really a new concept. How hard is it to design a box that works perfectly?

Again, from the Consumerist:
...nowhere on the website, while purchasing the Express Mail option did it state that items needed to be taken to the window/desk in order for the guarantee to apply.

I asked her, "Where on the box does it say that?" She then told me she had handed my form over to her supervisor.

I was given my full refund without any further discussion, but we did have to wait for half an hour while all this occurred. Although the supervisor did not want to give me the refund. She actually explained, "Letters get stuck up in the top of the box all the time. Sometimes, it takes days or even a week before we find them."

Consider yourself warned. Does FedEx have this problem? Or DHL?

To top it all off, one commenter claims:
This is absolutely true. I worked as a USPS letter carrier and when I had to empty collection boxes at least half the time there would be a letter or two stuck against the side of the box or at the very top of the box. To combat this, the USPS has a company send out test letters to see how long it takes for them to reach their destination. They also do random checks after you leave to make sure you grabbed every single letter. People have been fired over this.
Step 1: Design a box that doesn't meet customer or employee needs
Step 2: Do inspections to see how badly it works
Step 3: Blame and fire people

If you believe that, it's not a very encouraging thought process they are following. Typical bad management, eh?

Subscribe via RSS | Lean Blog Main Page | Podcast | Message Board


Labels: , , ,

Sunday, June 15, 2008

Lean in a Liverpool Hospital

Follow Royal’s example on waiting lists, hospitals told - Liverpool Daily Post.co.uk

Nice story from here in the UK (where I am right now), about an NHS hospital in Liverpool reducing surgery patient backlogs and delays through Lean. From the article:

Surgeons, nurses, porters, managers, anaesthetists and admin staff got together to think of ways to shorten the patient journey for orthopaedic surgery at The Royal Liverpool Hospital.

This meant the number of planned operations taking place within 18 weeks of referral improved from 35% in April, 2007, to 88% in March, 2008. The number of patients waiting over 11 weeks for in-patient planned treatment fell from 261 to nine.

Theatre start times before 9am have been improved by 20%, and total cancellations have been reduced by 7%. Patient cancellations have been reduced by 30%.

The hospital has been working by the