and its applications to improve animal welfare during transportation The basics of the lean six sigma concepts and its applications to improve animal welfare during transportation Krishnan Kolappaswamy, DVM, PhD, Certified Six Sigma Black Belt

Agenda What is LSS Tools used in LSS How to do a LSS project Example of a LSS project

Lean and Six Sigma (LSS) Lean is a manufacturing philosophy which shortens the timeline between the customer order and the product shipment by eliminating waste Waste? Defects Over production Waiting Transport Extra processing time Inventory Motion Intellectual

Lean and Six Sigma (LSS) Motorola first applied the concept of SS, when they had products that rarely passed QC first time - 1980 The goal of SS is to reduce variability and meet customer requirements every time

Tools in LSS Process map SIPOC Fishbone diagram Spaghetti diagram Pareto chart 5S Cause Effect Analysis Impact Effort Matrix PDCA Gemba ……and many more

So…..how can I initiate a LSS project What should I do?

5 step process – continuous improvement Define Measure Analyze Improve Control ……..called DMAIC process

Define Description of the project: Problem statement Goal statement Baseline data collection

Gemba (walk) The literal Japanese translation of GEMBA means “the real place” GO and SEE WHAT IS HAPPENING! A GEMBA can be used to: Identify waste and generate a Kaizen project Identify process problems and or improvements Can be physical or virtual

Process mapping Baking cookies Baking a cake Baking a turkey Turn on oven Put ingredients in bowl Mix ingredients Put in pan Bake Remove and cool Baking a cake Turn on oven Put ingredients in bowl Mix ingredients Put in pan Bake Remove and cool Baking a turkey Turn on oven Remove turkey from packaging Rub with spices Put in pan Bake Remove and cool

Process mapping Baking cookies and a cake: Are processed through the same basic steps Use the same processes Share common equipment

Measure Process mapping – current state Document, validate and confirm the current process Data collection on waste and defects

SIPOC

Example spaghetti diagram Before After Could be: Movement of documents through an office Movement of people walking around Spaghetti Charts make poor layouts and wasted motion obvious

Analyze Statistical tools to analyzed the data collected Histogram Pareto chart Box plots Root cause analysis 5 Why’s Cause Effect analysis

Improve Create future states PDCA concept

Impact effort matrix

Control To sustain the future state Process control Monitoring and response

The 5S’s Sort Straighten Shine Standardize Sustain

5S The Foundation of Lean 5S is a systematic approach to good housekeeping which helps to provide the proper attitude within the organization for better productivity and safety. Balancing and flow Finishing Value stream Framing 5S Foundation 5S helps to eliminate waste

5S applies to your system files

5S’ed computer files

Before

After

Before

After

Application of LSS principles during laboratory animal transportation

Application of LSS principles during laboratory animal transportation

LSS – Lab Animal Transportation

Improve Training on animal welfare during transportation Development of check list in case of an emergency situation Development of animal welfare check list as part of pre-trip check

Improvement data Total questions = 20 Total drivers = 19 Locations = Madison and Indy Score

Control Monitor for any mortality Act on the situation Analyze the cause Act on the RC

Acknowledgement Steve Jumps (Certified Lean Sigma Black Belt) Tammy Williams (Certified Lean Sigma Black Belt) Envigo Transportation Team