Lean Six Sigma Sample Analysis Process in a Microbiology Laboratory

• Published in: Journal of medical biochemistry Vol. 30; no. 4; pp. 346 - 353
• Main Authors: Stoiljkovic, Vojislav, Trajkovic, Jasmina, Stoiljkovic, Bratislav
• Format: Journal Article
• Language: English
• Published: Belgrade Versita 01.10.2011; Society of Medical Biochemists of Serbia; Society of Medical Biochemists of Serbia, Belgrade
• Subjects: DMAIC methodology; DMAIC metodologija; Lean; Microbiology; poboljšanje procesa; process improvement; Six Sigma
• ISSN: 1452-8258; 1452-8266
• DOI: 10.2478/v10011-011-0018-2

Faced with shrinking budgets, growing volumes, and personnel shortages, clinical laboratories are increasingly moving to automation to maximize output and efficiency. The best tool for improvement is the Lean Six Sigma concept. The concept reaps the full benefits of automation. A Lean process in a laboratory is focused on testing products and materials to deliver results in the most efficient way in terms of cost, speed, or both. The goal of a Lean laboratory is to use less effort, less resources and less time to test incoming samples. On the other hand, the Six Sigma concept provides process workflow and products/services without defects. The Lean Six Sigma approach analyzes laboratory workflow to help identify inefficiencies and uncover opportunities to free capacity, reduce turnaround time and lower costs. The assessment examines the end-to-end process looking closely at workflow as well as overall laboratory efficiency. The proven techniques of Lean and Six Sigma enhance productivity in the laboratory environment and ensure the best outcomes. This article analyzes a particular process, defines the approach, and gives a review of results obtained by deployment of the Lean Six Sigma concept. The article discusses a sample analysis process in a microbiology laboratory. A traditional process that applies standard analysis methods has a number of non-value-added activities, takes too much time, and has opportunities for defects. By mapping an existing process using a SIPOC model, 12 activities were identified. With the use of Lean tools four non-value-adding activities, which are not needed if a new system is used, were identified. Six activities had opportunities for improvement in terms of significant reduction in process time, and saving resources. Only two activities in the existing traditional process, with the use of standard analysis methods were optimally solved, and this did not require redesign or removal. The application of Lean Six Sigma concepts and automated analysis systems on a new process led to only nine activities in the process that now takes much less time and uses less resources. This article presents a description of the main principles, practices, and methods used in Lean and Six Sigma. The Lean tools particularly discussed here are 5s and spaghetti diagram. For Six Sigma, DMAIC methodology is used, and a review of applied quality tools for certain process improvement phases is given. Suočene sa smanjenjem budžeta, rastom obima posla i nedostatkom osoblja, mikrobiološke laboratorije se sve više okreću automatizaciji, sa ciljem maksimizacije učinka i efikasnosti. Najbolji koncept poboljšanja procesa danas je Lean Six Sigma. Ovaj koncept izvlači brojne koristi iz automatizacije. Lean proces u laboratorijama se usredsređuje na ispitivanje proizvoda i materijala, da bi se na efikasan način dobili najbolji rezultati što se tiče vremena ciklusa i troškova, ili obe komponente zajedno. Planirani rezultat Lean laboratorije podrazumeva manje napora, manje resursa i manje vremena za ispitivanje uzoraka, sa ciljem oslobađanja ljudskog potencijala. S druge strane, Six Sigma koncept obezbeđuje tok procesa i proizvoda/usluga bez defekata. Lean Six Sigma pristup analizira tok aktivnosti u laboratorijama radi utvrđivanja neefikasnosti i otkrivanja prilika za oslobađanje kapaciteta, kao i radi smanjenja vremena i troškova. Dokazane Lean Six Sigma tehnike povećavaju produktivnost u okruženju laboratorije i osiguravaju najbolje rezultate. U radu se analizira identifikovani značajni proces, definiše pristup i daje pregled rezultata dobijenih korišćenjem Lean Six Sigma koncepta. Članak analizira proces analize uzoraka u mikrobiološkoj laboratoriji. Tradicionalni proces koji primenjuje standardne metode analize obuhvata jedan broj aktivnosti koje ne dodaju vrednost, zahteva mnogo vremena i pruža prilike za pojavu defekata. Snimanjem postojećeg procesa korišćenjem SIPOC modela identifikovano je 12 aktivnosti. Primenom Lean alata identifikovane su četiri aktivnosti, koje nisu potrebne ako se koristi novi sistem. Šest aktivnosti pruža prilike za poboljšanje u pogledu značajnog smanjenja vremena trajanja procesa i uštede resursa. Samo dve aktivnosti u postojećem tradicionalnom procesu su bile optimalno rešene korišćenjem standardnih metoda i nisu zahtevale redizajn ni uklanjanje. Primena Lean Six Sigma koncepata i automatizovani sistemi analize u novom procesu utvrđuju samo do 9 aktivnosti u procesu, pa je tako potrebno mnogo manje vremena i resursa. U ovom radu se daje opis osnovnih principa, praksi i metoda korišćenih u Lean i Six Sigma konceptu. Posebno su analizirani Lean alati 5S i spaghetti dijagram. Za Six Sigma koristi se DMAIC metodologija i daje se pregled primenjenih alatki za poboljšanje kvaliteta za pojedine faze poboljšanja procesa.