Aug
30
2010
0

Some longer courses which are starting soon …

With September coming and children returning to school and students starting or returning to college, many people begin to think of their own training needs. There has never been as much emphasis on upskilling for all of us.

Here in SQT we find a big increase in course bookings at this time of year. I just want to draw your attention to some of the longer courses commencing shortly. Here’s a quick list and I’ve inserted a link back to the course page, where further details can be found. I’ve included public courses of four days or more duration.

Black Belt – HETAC level 8, commencing 12th October Dublin

Green Belt – HETAC level 7, commencing 22nd September Dublin and 19th October in Cork

Green Belt – HETAC level 6, commencing 22nd September Dublin and 19th October in Cork

NEBOSH International Diploma in Occupational Health and Safety, commencing 23rd September Dublin

NEBOSH International General Certificate in Occupational Health and Safety, commencing 28th September Dublin

Certified Energy Management – AEE, commencing 21st September Dublin

Train the Trainer, National Register of Trainers – FETAC level 6, commencing 12th October Dublin and 16th November Limerick

Quality Management Systems Auditor/Lead Auditor – IRCA, commencing various dates in the Autumn in Dublin and Limerick

Lean Manufacturing Tools – FETAC level 5, commencing 14th September Dublin

IEMA Approved Foundation Course in Environmental Auditing (Ireland), commencing 11th October Dublin

IEMA Approved Advanced EMS Auditing Course (Ireland), commencing 22nd November Dublin

Occupational Health & Safety Management System Lead Auditor, commencing 8th November Dublin

Good luck to all.

Jun
24
2010
0

Lean Six Sigma includes more than the usual suspects!

Lean Six Sigma has expanded its horizons to more than the usual suspects in terms of Projects. Traditionally, it was all about manufacturing and improving quality or reducing cycle times. However our Blackbelt and Greenbelt HETAC Programs have included some very unique and diverse projects in a variety of different Service and Transactional Industries. Examples include:

  • Improved Credit Card Fraud Processing by reduced input entries by 44%
  • Improved an EU Import Testing Process to meet a 23-day target
  • Green Statements – Removed the need for such a high volume of printed statements
  • Reduced number of errors relating to post being scanned to the wrong queue for distribution
  • Reduced Direct Debit Write Offs
  • PUK Code Calls – 15% reduction in customers’ calls to customer care for help
  • Standardization of Shipment Process resulting in not having to run an extra shift and resultant cost savings
  • Energy Saving Project – Reduction of carbon emissions by 23%
  • The process of screening referrals – increased management visibility and reporting of process performance resulting in less queries and non-value added investigation and tracking
  • Process Improvement is Process Improvement irrespective of the process and industry. The flexible and practical DMAIC* methodology of Lean Six Sigma has proven itself in this regard.

    In the last round of completed Lean Six Sigma projects, cost savings of €8,808,801 were achieved over seventy six projects … an average of €116k per project

    An average of €116k from projects that included more than the usual suspects!

    *(DMAIC = Define-Measure-Analyse-Improve-Control)

    May
    11
    2010
    1

    The power of the simple checklist

    My son referred me to this December 2007 article by Atul Gawande, an American doctor and journalist, in the New Yorker magasine. The article is entitled, ‘The Checklist‘ with a sub heading, ‘If something so simple can transform intensive care, what else can it do?’

    This simple tool, the checklist, is introduced early on our Lean Six Sigma and Continuous Process Improvement training courses. This simple tool is no new, ground-breaking, expensive medical treatment but this article shows how powerful a tool it can be.

    Gawande’s article is well-worth reading but I have to warn you that it’s long. Here are extracts:

    A decade ago, Israeli scientists published a study in which engineers observed patient care in I.C.U.s for twenty-four-hour stretches. They found that the average patient required a hundred and seventy-eight individual actions per day, ranging from administering a drug to suctioning the lungs, and every one of them posed risks. Remarkably, the nurses and doctors were observed to make an error in just one per cent of these actions—but that still amounted to an average of two errors a day with every patient. Intensive care succeeds only when we hold the odds of doing harm low enough for the odds of doing good to prevail. This is hard.

    This is the reality of intensive care: at any point, we are as apt to harm as we are to heal. Line infections are so common that they are considered a routine complication. I.C.U.s put five million lines into patients each year, and national statistics show that, after ten days, four per cent of those lines become infected. Line infections occur in eighty thousand people a year in the United States, and are fatal between five and twenty-eight per cent of the time, depending on how sick one is at the start. Those who survive line infections spend on average a week longer in intensive care. And this is just one of many risks.

    In 2001, though, a critical-care specialist at Johns Hopkins Hospital named Peter Pronovost decided to give it
    (checklists as used in flying) a try. He didn’t attempt to make the checklist cover everything; he designed it to tackle just one problem, … line infections. On a sheet of plain paper, he plotted out the steps to take in order to avoid infections when putting a line in. Doctors are supposed to (1) wash their hands with soap, (2) clean the patient’s skin with chlorhexidine antiseptic, (3) put sterile drapes over the entire patient, (4) wear a sterile mask, hat, gown, and gloves, and (5) put a sterile dressing over the catheter site once the line is in. Check, check, check, check, check. These steps are no-brainers; they have been known and taught for years. So it seemed silly to make a checklist just for them. Still, Pronovost asked the nurses in his I.C.U. to observe the doctors for a month as they put lines into patients, and record how often they completed each step. In more than a third of patients, they skipped at least one.

    The next month, he and his team persuaded the hospital administration to authorize nurses to stop doctors if they saw them skipping a step on the checklist; nurses were also to ask them each day whether any lines ought to be removed, so as not to leave them in longer than necessary. This was revolutionary … The new rule made it clear: if doctors didn’t follow every step on the checklist, the nurses would have backup from the administration to intervene.

    Pronovost and his colleagues monitored what happened for a year afterward. The results were so dramatic that they weren’t sure whether to believe them: the ten-day line-infection rate went from eleven per cent to zero. So they followed patients for fifteen more months. Only two line infections occurred during the entire period. They calculated that, in this one hospital, the checklist had prevented forty-three infections and eight deaths, and saved two million dollars in costs.

    Pronovost recruited some more colleagues, and they made some more checklists. One aimed to insure that nurses observe patients for pain at least once every four hours and provide timely pain medication. This reduced the likelihood of a patient’s experiencing untreated pain from forty-one per cent to three per cent. They tested a checklist for patients on mechanical ventilation, making sure that, for instance, the head of each patient’s bed was propped up at least thirty degrees so that oral secretions couldn’t go into the windpipe, and antacid medication was given to prevent stomach ulcers. The proportion of patients who didn’t receive the recommended care dropped from seventy per cent to four per cent; the occurrence of pneumonias fell by a quarter; and twenty-one fewer patients died than in the previous year. The researchers found that simply having the doctors and nurses in the I.C.U. make their own checklists for what they thought should be done each day improved the consistency of care to the point that, within a few weeks, the average length of patient stay in intensive care dropped by half.

    The checklists provided two main benefits, Pronovost observed. First, they helped with memory recall, especially with mundane matters that are easily overlooked in patients undergoing more drastic events … A second effect was to make explicit the minimum, expected steps in complex processes.

    Gawande stated that Pronovost is hardly the first person in medicine to use a checklist, but that he was among the first to recognize its power to save lives and take advantage of the breadth of its possibilities.

    Gawande then described how Pronovost then took his findings on the road, showing his checklists to doctors, nurses, insurers, employers—anyone who would listen. He spoke in an average of seven cities a month while continuing to work full time in Johns Hopkins’s Hospital. But this time he found few takers.

    There were various reasons. Some physicians were offended by the suggestion that they needed checklists. Others had legitimate doubts about Pronovost’s evidence. So far, he’d shown only that checklists worked in one hospital, Johns Hopkins, where the I.C.U.s have money, plenty of staff, and Peter Pronovost walking the hallways to make sure that the checklists are being used properly. How about in the real world—where I.C.U. nurses and doctors are in short supply, pressed for time, overwhelmed with patients, and hardly receptive to the idea of filling out yet another piece of paper?

    Michigan Health and Hospital Association went ahead adopted Pronovost’s ideas in 2003. The project became known as the Keystone Initiative.

    In December, 2006, the Keystone Initiative published its findings in a landmark article in The New England Journal of Medicine. Within the first three months of the project, the infection rate in Michigan’s I.C.U.s decreased by sixty-six per cent. The typical I.C.U. … cut its quarterly infection rate to zero. Michigan’s infection rates fell so low that its average I.C.U. outperformed ninety per cent of I.C.U.s nationwide. In the Keystone Initiative’s first eighteen months, the hospitals saved an estimated hundred and seventy-five million dollars in costs and more than fifteen hundred lives. The successes have been sustained for almost four years—all because of a stupid little checklist.

    Gawande stated that Pronovost has since had requests to help Rhode Island, New Jersey, and Spain do what Michigan did.

    Gawande suggests we consider: there are hundreds, perhaps thousands, of things doctors do that are at least as dangerous and prone to human failure as putting central lines into I.C.U. patients. It’s true of cardiac care, stroke treatment, H.I.V. treatment, and surgery of all kinds. It’s also true of diagnosis, whether one is trying to identify cancer or infection or a heart attack. All have steps that are worth putting on a checklist and testing in routine care. The question—still unanswered—is whether medical culture will embrace the opportunity.

    I (Gawande) called Pronovost recently at Johns Hopkins … I asked him how much it would cost for him to do for the whole country what he did for Michigan. About two million dollars, he said, maybe three …

    This is the end of my extracts from the article. In my opinion two million, maybe three for a country the size of the USA seems like petty cash when one observes the results being achieved and in the context of the overall cost of US healthcare.

    Can you imagine if we achieved these results here in Ireland!

    I highly recommend that you read the full article, (link at top of the post).

    More here on Gawande. Gawande’s book; ‘The Checklist Manifesto: How to Get Things Right’, was released in 2009. This book reached the New York Times Hardcover nonfiction bestseller list this year.

    Any comments on use of checklists?

    May
    05
    2010
    0

    NEBOSH and Six Sigma Black Belt Courses in the Autumn

    I know we’ve only just celebrated the first of May and here I am talking about courses in the Autumn. Really I just want to get people thinking ahead for the longer courses which will commence in the Autumn. I have three courses specifically in mind and will give a little information on each:

    1 NEBOSH International General Certificate in Occupational Health and Safety

    This NEBOSH accredited course is designed for managers, supervisors and employee representatives. It focuses on international standards and management systems to provide a broad understanding of health and safety principles and practices, enabling candidates to effectively discharge workplace health and safety responsibilities.

    The course is suitable for those embarking on a career in health and safety, but also provides a valuable foundation for further professional study. According to NEBOSH this course is at Level 3 in the UK, equivalent to Level 5 on the Irish National Framework of Qualifications. (Page 2 of the following document compares qualifications in the UK and Ireland.)

    On successful completion, a Certificate holder with five years experience in a Health and Safety role may apply for Technician membership (Tech IOSH) of the Institution of Occupational Safety and Health (IOSH), the largest UK professional body in the field. The Certificate also satisfies the academic requirements for Associate membership (AIIRSM) of the International Institute of Risk and Safety Management.

    The Certificate is a 12-day taught course commencing this September, preparing candidates for exams in March 2011.

    2 NEBOSH International Diploma in Occupational Health and Safety

    The International Diploma, also accredited by NEBOSH, is designed for health and safety professionals who require a high degree of managerial and technical competence to advise on effective management of risk across the range of employment sectors. According to NEBOSH this course is Level 6 in the UK, equivalent to Level 8 on the National Framework of Qualifications.

    On successful completion, the Diploma holder may apply for Graduate membership of IOSH, (Grad IOSH). This is the first step to becoming a Chartered Member of IOSH (CMIOSH). This qualification is also accepted by the International Institute of Risk and Safety Management as meeting the academic requirements for full membership (MIIRSM).

    The International Diploma is a blended learning course with 14 workshop days commencing this October, preparing candidates for examinations in January 2011 and July 2011.

    3 Six Sigma Black Belt, HETAC accredited

    Six Sigma is a comprehensive and highly effective strategy for achieving and sustaining business success. Six Sigma delivers bottom line savings, project by project, in an organised, proactive and highly transparent manner. Six Sigma is driven by a close understanding of customer needs, disciplined use of knowledge, facts and statistical analysis and diligent attention to a methodology to improve or reinvent business processes.

    Our Black Belt 20 day programme consists of 4 days training per month, over 5 months. The unique feature of this Black Belt programme is that HETAC certification is only achieved on completion of a major project, documenting application of the learning tools and evidence of the savings generated. Typical Black Belt projects are yielding savings of €250,000 per project. The course is at Level 8 on the National Framework of Qualifications.

    Our autumn Black Belt course is commencing in October. Training will finish in March 2011 with project completion due within 12 months.

    We will have a wide range of shorter courses on offer over the coming months. Since these three courses are longer and thus the decision is bigger in terms of time/cost, I thought it was worthwhile to write separately about them. The three titles above are links to the relevant web page giving more detail on each course.

    Please contact me, lcollison@sqt.ie if you have any queries.

    Apr
    26
    2010
    0

    Recent Six Sigma Projects save almost €9 million

    Congratulations to all recent recipients of HETAC awards for their Six Sigma training. Last month ninety people received awards over the four HETAC accredited Six Sigma courses.

    Seven people completed Black Belt training. Their projects realised cost savings of on average €300,576 per project.

    Four people completed Back Belt, Service and Transaction projects. Their projects averaged €71,968 savings.

    Sixty Five people completed Green Belt, HETAC level 7 projects. The average cost saving was €98,722 per project.

    Fourteen people completed the Green Belt HETAC level 6 course, which involves a case study rather than completing a project.

    In all cost savings of a total of €8,808,801 were achieved over seventy six projects.

    There are many other Six Sigma projects underway. People are working hard completing these and achieving more very tangible cost savings for their companies. These savings are critical for the survival of many companies in the economic realities of 2010 Ireland.

    Without doubt, Six Sigma methodology is now proving to be a very important tool.

    Dec
    03
    2009
    1

    Lean Six Sigma ‘Wall of Pain’

    Eamon, one of our Lean Six Sigma tutors wrote the following:

    Given the relenting pressure on all businesses to drive costs downwards and improve their competiveness the question is where do we start? Which areas should we focus on?

    A very simple technique is what they call the ‘wall of pain’. This is whereby the Management Team based on their every day experiences list the top 10 activities which they consider a pain in the …

    This top 10 is then correlated against the annual goals and objectives in terms of their impact to shortlist the top 3 opportunities and equivalent continuous improvement projects. This correlation uses a scoring method as illustrated below.

    Screen shot 2009-12-01 at 18.47.51

    Whether we undertake the Project using Lean Six Sigma or another Continuous Improvement Program depends on the company preference … the important thing is that we have a starting point!

    Written by Eamon OBearra in: Lean Six Sigma |
    Nov
    30
    2009
    0

    Kanban – The Milk Example

    There
    Photo owned by devriesm (cc)

    Think of something at home that you never want to be without. Recently, Paul volunteered that his family never run out of milk. How do they ensure that that happens? They keep 2 x 2 litre containers of milk in the fridge. As soon as one is empty, it is left out and prompts the next person going to the shops to collect a 2-litre container of milk. Simple? They are never without milk.

    Oh, by the way, Paul’s family have never heard of kanban.

    As with many lean principles, they are derived from simple common sense. A good kanban system ensures continuous supply of material. The word ‘kanban’ means ‘signal’. A kanban signal is a trigger to replenish material.

    The most common type of kanban is a 2-bin kanban. 2 bins are used for each item in a storage location. Each container is filled with a quantity to cover usage over a set period of time. One ‘bin’ must be emptied before using the second. The empty bin triggers a signal.

    The signal can be the bin itself, a card, a fax etc and should follow a standard process.

    Bin sizes are calculated using a combination of the usage, delivery/collection frequency, supply lead time and batch size.

    The target in many lean companies is to minimise bin sizes by increasing collection/delivery frequency and reducing batch sizes.

    Through the application of kanban, companies can expect to reduce inventories and eliminate downtime due to material shortages.

    This is one of the many tools delivered in our FETAC Lean Manufacturing Tools training course helping to minimise waste in participating companies. Click on the link for more information.

    Written by Steve Halpin in: Lean Six Sigma |
    Oct
    07
    2009
    0

    Lean Six Sigma: ‘Voice of the Customer’

    Times are changed and it’s certainly considered a buyers market out there at the moment. While this is true of those buying houses or second-hand cars, it’s also true across all goods and services. Early 2009 saw the mass exodus to customers migrate to the north to purchase goods. A new price sensitive customer has appeared, one who had not been seen during the Celtic Tiger years.

    So what does this mean? Customer needs change over time. What was relevant last year may not be what customers now want. What were customer needs for mobile phones ten years ago? What are those needs today? Organizations must continuously listen to the ‘Voice of the Customer’ and have a willingness to change in order to deliver those customer needs.

    With Six Sigma it all starts with the Customer – Who are those customers and what do they want? What’s really important to them and what’s the nice to have?

    The Kano Model states that all customer needs can be classified as Dissatisfiers, Satisfiers and Delighters. See diagram below:-

    foo

    The Kano model can be used to identify where to focus Six Sigma projects in your organization. For example, customers may want to their insurance premium costs to be kept to a minimum (Dis-satisfier) yet don’t mind if their policy takes 10 days to issue (Delighter) but they still want to receive the standard policy (Satisfier). So a Green Belt or Black Belt could review the core processes which support the costs of issuing policies and reduce waste or re-work in order to reduce policy costs. This would meet the basic customer need and ensure they are not ‘Dissatisfied’. Issuing standard polices will ensure they are ‘Satisfied’. Finally, if you’ve achieved all this and still can issue policies by 7 working days then you would be going above their expectations and ‘delighting’ them.

    With some organizations now advertising their Irish or UK based call centres for handling customer calls perhaps they’ve been listening to their ‘Voice of the Customer’? Perhaps they identified out-sourced call centres as a customer dissatisfier and made the decision to change their business to meet their customer needs.

    Written by Siobhan Foley in: Lean Six Sigma |
    Sep
    30
    2009
    0

    Six Sigma Cost Savings

    Billetes
    Photo owned by Eric Caballero (cc)

    To date, 133 people have completed their HETAC accredited Lean Six Sigma training. (Our Lean Six Sigma programmes became HETAC accredited last year.)

    A look at the cost savings achieved from the Lean Six Sigma projects shows the average cost savings per project were:

    Black Belt €242,865
    Black Belt (Service & Transaction) €118,083
    Green Belt €103,853

    One Green Belt project resulted in a cost saving of over €5 million (€5,203,659 to be precise).

    Congratulations to all on completing successful projects and achieving their HETAC awards.

    A lot more people are at various stages of Lean Six Sigma training. Some are just completing projects whilst others have just started, with many in between.

    Good luck to all.

    Written by Lily in: Lean Six Sigma |
    Sep
    17
    2009
    1

    Six Sigma and Wine … go together

    I’m always meeting people who think that Six Sigma is only for large multinational manufacturing companies. The following is testament to that not being true;

    A friend of mine who works for Google in the US told me of a speaker who was coming to talk them in their HQ in Mountain View. His name is Kaj Ahlmann and he runs a ranch and winery in northern California.
    “Good for him!” you might say, but what’s this got to do with Six Sigma? Well, the ranch is called Six Sigma Ranch. Kaj is a Six Sigma Black Belt who spent his business career with GE. In 2000, he bought some land and devoted his energy to doing things the “right” way to make a world-class wine. This “right” way is Six Sigma.

    Screen shot 2009-09-16 at 22.09.05

    Below is a piece taken from the website www.sixsigmaranch.com on their approach to wine making

    Screen shot 2009-09-16 at 22.09.2

    Kaj always had a desire to set up a winery and vineyard and now he is living the dream. After looking at the ranch website, any Six Sigma practitioner will realise that Six Sigma is a step on the way to achieving any goal. Six Sigma principles, tools and disciplines can be applied to any sort or business in any industry at any time…

    Written by Geoff in: Lean Six Sigma |

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