Dr. Mohamed discusses implementing Lean principles like Kanban

Dr. Rashad A. Mohamed
CGBLSS, TQMD, CPHQ

Multiple Wastes
Cycle time 5 MinutesCycle time 5 Minutes Cycle time 25 Minutes Cycle time 5 Minutes
C
Do we need Lean?

Multiple Wastes
Do we need Lean?
Cycle time 25 Minutes

Multiple Wastes
Waste1: Long Waiting
Input – To DO
Feedback
Do we need Lean?

Multiple Wastes
Waste1: Long Waiting Waste 2: Un-Used Resources
Input – To DO
Feedback
Do we need Lean?

Multiple Wastes
Input – To DO
Feedback
Waste 3: Over producing
Stressed Operator
Stressed Operator
Waste 3: Over processing
Stressed Operator
Do we need Lean?

Multiple Wastes
Input – To DO
Feedback
Stressed Operator
Stressed Operator
Waste 3: Over processing
Stressed Operator
Large Quantity of Work in Process – WIP
Waste 4 : Inventory
Do we need Lean? Kanban Can Help

Lean Principles
Medication Dispensing
By Pharmacy
Medication Purchasing
By Supply chain
Inventory
CustomerSupplier This is Pull

Lean Techniques
Cross Training &
Parallel Processing
Training of Employee A to do task of
Employee B and training of Emp. B to
do task of Emp. A
Parallel Process with designed steps
to happen at the same time
(Simultaneously)
with decreasing Lead Time
Kanban &
Supermarkets
Kanban, FiFo lanes,
and supermarkets are the
backbone of many pull
system
Workload Balancing &
Demand Leveling
Work Balancing or Line Balancing
involves balancing the work rate
between sub-processes in order to
efficiently match customer demand
or takt time.
The idea is that process is always on
time but never idle.
Visual Management & 5S
the use of techniques that will enable a
person to immediately recognize normal
and abnormal states in a process
Change over
Reduction
Reduce the combined amount of
Set-up and Start-up time it takes
to change a process from running
one product to running the next one
Work Cell Design
Resources in work environment,
organized to
 improve process flow.
 Increase efficiency.
 eliminate wastage.
Single Piece Flow
Vs. Batching
One-piece flow means that
parts are moved through
operations from step-to-step
with no work in process in
between
Standard Work
By documenting the current best practice,
standardized work forms the baseline for kaizen or
continuous improvement.
As the standard is improved, the
new standard becomes the baseline for further
improvements, and so on. Improving
standardized work is a never-ending process

Kanban
Kanban Board
Kanban System
 Inventory
 Production
 Purchasing
 Other

Kanban Principles
Full Capacity Process

Kanban is the Japanese word for “ visual signal or card ”.
 A Kanban Board is a workflow visualization tool that allows you to
actually see the flow of the tasks that lie ahead.
 A Kanban board helps you to keep your to-do list organized,
color-coordinated and easy to evaluate just by looking at it.
 Most boards are created on a simple whiteboard and have three
sections titled To-Do, Doing and Done.
Kanban Visual Board System

Kanban Hospital Applications
 Project Management
 Pharmacy
 Supply chain & Stock rooms
 Approval Office
 Admission Office
 Nursing Stations
 Case Managers
 Discharge Planning
 Operating Rooms
 Radiology Department
 Physiotherapy Sessions
 Kitchen
 IT Department
 Maintenance Department
 Finance (Invoices -Reimbursement)
 Marketing Department
 HR Department
 Other

Kanban Visual Board System
1
2
3

Kanban Dual System (IT, Maintenance)
Planned
Tasks
Ongoing
Requests

Kanban Board ….. Step by Step
Get the
Task
Lists

Add
Statuses

Add some
Processes
or Sub-
processes

Add
Queues

Add
Work-in
Progress
(WIP)
Limits

Start
steady flow
by Pull
Mechanism

Comment

Consider
Bottlenecks

2

1
Pull the
Tasks with
consideration
of WIP Limits

Consider
Waiting

Consider
Priority
& Urgent
Tasks

Use
Resources
wisely
according
to priority

Kanban is the Japanese term for Just in Time Replenishment.
This is a visual tool to refill inventory when and only when needed.
As refill is done only when needed, there is no excess or shortage.
Inventory is always kept lean and minimum.
Kanban Inventory System

 Kanban system had been used successfully since 1940 in manufacturing
Industries.
It had been adopted in super markets also. It is a common sight to see long
racks where bakery items and milk are kept in the super markets.
 Items are stocked from the back as it is consumed from the front.
(First in, first out)
 The same process can be adopted in Hospitals & Health care industry.
 Most Common used Tools
 Colored Kanban Cards (Single Bin)
 Colored Coded Two-Bin Kanban System)

Single Bin (Colored Kanban Cards)

 Important items like medicines, syringes can be
put on a two bin in the rack.
While the front bin is being used,
There is a full bin waiting at the back.
 As soon as the first bin becomes empty, it will
be pushed to the back or top shelf for refilling.
 The full bin that was in the back will come to
the front now and it will be being consumed.
Color-Coded Two-Bin Kanban system

Color-Coded Two-Bin Kanban system

Sliding shelves system (First In First Out)

 An electronic Kanban system
Automates the process of ordering
When the bin becomes empty, whoever consumed the last item
Move the bin to back or top shelf.
 Scan a bar code with a mobile app or a mobile card reader.
This will trigger the signal to the suppliers to start the refill
process.
Suppliers will get email or a text message that the bin needs to
be re stocked.
Electronic Kanban (E-Kanban) System

Scanning the code system
Electronic Kanban (E-Kanban) System

https://youtu.be/uIw7IlxlKN8
https://youtu.be/WULe9bg31ps
LEAN SYSTEM (KANBAN)
2 Bin Training Video

 Hospital stores managers will be more comfortable in holding large stock
of all the items to be on the safer side. But that will lead to excess inventory and
expired items.
 Log time to Convince them that a lean inventory system is
safe and reliable.
 Getting the suppliers to follow the Kanban process will need
training effort.
 There should be discipline in scanning the card to record the
transaction. (Standard of work)
 The system used should have built in checks to avoid
duplicate transactions leading to financial issues.
Challenges in Implementing Kanban System

 Start it simple with few items and few suppliers.
 Expand the scope as it scales well and all the
parties are getting familiar with the system.
 Don’t Complicate Your Kanban board as it is
used to help make life easier, so you shouldn’t add too
much information to the board that isn’t needful
How to Start implementing a Kanban System

Dr. Mohamed discusses implementing Lean principles like Kanban

Dr. Mohamed discusses implementing Lean principles like Kanban

Recommended

Recommended

More Related Content

Similar to Dr. Mohamed discusses implementing Lean principles like Kanban

Similar to Dr. Mohamed discusses implementing Lean principles like Kanban (20)

Recently uploaded

Recently uploaded (20)

Dr. Mohamed discusses implementing Lean principles like Kanban