Work place organization

Jignesh Padia

Session Brief

• Vision

• Types of control / improvements

• What anyone………….CANDO

• Industry jargon for workplace organization

• Brainstorming!

• Audit!

• PDCA – Plan Do Check Act

Vision for organized workplace

No– Wandering / Searching

– Waiting / Delays

– Obstacles / Detours

– Extras

– Injuries

– Waste

A work environment that is

self-explaining

self-ordering

self-regulating

self improving

What is different?

IDs & LabelsDirectionsInstructionsDisplays

LightsVisual control boardsAlarmsSignals / Indicators

Advanced lean techniques• Kanban• Container size• Pallet size• Aisle width• Poka-Yoke

LimitsDetectorsSensorsTemplates

Passive Assertive Aggressive Absolute

CANDO

• Cleanup– Inventory, paper, furniture, tools, memos, manuals, rubbish, filing

cabinets

• Arranging– A place for everything……– Minimize reaching, bending, walking etc– Easy to hand, labelled, classified, and visible– Aim to avoid double handling

CANDO

• Neatness– 5 minute cleanup routines– Servicing of machines / equipment– Assign responsibilities for the area

• Discipline– Regular audit– Reward & recognition

• Ongoing Improvement– Continuous– Establish clear standards– Identify root cause for any failures

Industry jargon for workplace organization!

Set in order

Shine

Sort

Standardize

Sustain

Sort

• Ensuring each item in a workplace is in its proper place or identified as unnecessary and removed.

• Sort items by frequency of use

• Get rid of unnecessary stuff– Bare essentials for the job

– Red Tag system

– Can tasks be simplified?

– Do we label items, and dispose of waste frequently?

Set in order

• Time spent looking for things, putting away

• Arrange materials and equipment so that they are easy to find and use– Prepare and label storage areas

– Use paint, outlines, color-coded

– Consider ergonomics of reaching items

– Frequent, infrequent users

Strategies for effective Set In Order are:

Set in Order Set in Order –– (Seiton)(Seiton)

– Painting floors / Segregating Areas

– Outlining work areas and locations

– Bulletin boards / White boards

– Modular shelving and cabinets

“A PLACE FOR EVERYTHING AND EVERTHING IN ITS PLACE”

Shine

• Repair, clean & shine work area - No spillage / dirt / defects!

• Maintenance problems identified before they cause problems.

• Schedule for cleaning, calibration, servicing

• Cleaning inspection checklists

• See workspace through customers’ eyes

Shine / Cleaning……

Cleanliness involves cleaning every aspect of the Organization and the removal of dirt, dust, cardboards, scraps & garbage.

Key Deliverables

A clean Systematic Organization results in increased safety and efficiency.

Increased Safety

Increased Efficiency

Standardize

• Formalize procedures and practices to create consistency and ensure all steps are performed correctly.

• Otherwise improvements from first 3 is lost

• Everyone knows what they are responsible for doing, when and how

• Visual 5S – see status at a glance

• No wasted resources

Sustain

• Keep the processes going through training, communication, and organization structures

• Allocate time for maintaining

• Create awareness of improvements

• Management support for maintaining

• Training & Rewards

Entropy

• Entropy is a measure of the number of ways in which a system may be arranged, often taken to be a measure of "disorder“

• The higher the entropy, the higher the disorder

• Movement towards order requires energy.

• Take the example of a shirt, folding it takes more energy than throwing it on the ground. Another way of saying this, is that creation of a disorganized state is spontaneous, that is, it doesn’t require energy.

• Entropy is called the law of disorder. In a system, a higher energy level is required to sustain order.

Entropy at work! Energy at work!

Visual management system allows analysts to quickly find and test samples.

Thank You

Common problems…………

Common problems?

• Samples needed were stored in two different areas·

• LIMS / System doesn't record what type or quantity of bottle(s) / samples received·

• Time spent looking (searching) for samples·

• Time spent waiting to accumulate a larger batch·

• Clumsy transfer of samples from carts to shelves to Freezers / Incubators / Shakers and back·

• Time spent keeping everything in numeric order·

• Time spent shuffling samples for multiple tests·

• Printing lots of little labels ·

• Labels don't stick to bottles; use tape and rubber bands etc·

• Multiple drop offs and motion needed to deliver samples to all locations.• Checking pH on samples that should be correct· • Lots of transferring of samples on and off carts from shelves, then back onto shelves or

in coolers· • Sorting through pending list to determine which samples need to be run· • Clients wait for test results to be completed/entered· • Coolers are full; have to move stuff around to get what you need· • Samples are "misplaced" between Analyst 1 and Analyst 2· • Stacking trays make it difficult to get samples· Multiple ways of labeling bottles· • Forms filled out incorrectly by the client·

• 16 new tray carts will be used to hold and process samples.

• Clearly labeled / barcoded for easy visual reference. This will allow for better utilization of floor & shelf space as well as make it simple for analysts to find and process needed samples.

• Consolidated 13 drop sites to 9. E.g. Consolidated all General Chem, moved Fluoride drop areas and reorganized areas using 5S principles. Drop areas for samples are clearly defined for each test type.

• Trays will be used to transfer samples from cart to drop site. Drop location allows for visual management of work flow.

• Each sample will be barcoded and scanned in and out of storage locations. Sample location information will be stored in the new LIMS for easy access.

• Analysts will no longer search for the needed samples.

• New LIMS will provide metrics for tracking time for each sample, so bottlenecks and problems can be identified and fixed.

• Program was changed to print two rows of labels to stick to bottle. This simplifies the labeling process. Once the new LIMS is operational, barcodes with permanent label adhesive will placed on the top and sides of the bottle. Samples will be tracked in the system - no extra labels needed.

• Standard work created for the following processes: delivery, sample handling, storage of samples, disposal of samples, labeling of samples.