Heating & Cooling Service Experts Refrigeration How to Control an Ergonomics Program through Six-Sigma Methodology Ana M. Ferreras Keith White, Ph.D., CPE, CEM Heating & Cooling Service Experts Agenda Ø Background Ø Ergo-Sigma Model Ø DMAIC Process Ø Steps Ø Tools Ø Conclusion Refrigeration Heating & Cooling Service Experts Refrigeration Background Ø Six Sigma is.. · a customer focused, · well defined problem solving methodology, · supported by a hand full of powerful analytical tools. Ø Continuous improvement is driven by the execution of carefully selected projects Heating & Cooling Service Experts Ergo-Sigma Structure Management Vision Strategic Planning Six-Sigma DMAIC Daily Control PDCA/Kaizen Teams Refrigeration Heating & Cooling Service Experts Refrigeration DMAIC—Five Step Process Define Control Improve Measure Analyze Heating & Cooling Service Experts Refrigeration Six-Sigma Ø Define – Understand the problem (limit scope) Ø Measure – Quantify the ergonomics risk factors Ø Analyze – Understand the root causes of ergonomics risk factors Ø Improve – Determine how to best reduce risk factors, and implement the improvements Ø Control –Measure results of the improved process to ensure that improvements have been implemented Heating & Cooling Service Experts Refrigeration Is 99% Good Enough? ü15 minutes of unsafe drinking water each day ü5,000 incorrect surgical operations per week ü200,000 wrong drug prescriptions each year üNo electricity for almost 7 hours each month Capability Long-Term Yield 3 Sigma 93.32% 4 Sigma 99.38% 6 Sigma 99.99966% Standard Historical Standard Current Standard New Standard Heating & Cooling Service Experts Refrigeration Effective Six Sigma must… 1. Ergonomics program must exist and be in use. lYou can’t improve a process that doesn’t exist 2. The program must be in control statistically. lMust have some track record of performance 3. The program may then be improved. lReduce risk factors in the process Heating & Cooling Service Experts Refrigeration DMAIC Stage ØGoal setting of sub-teams ØIdentifying stakeholders ØSelect team and assign task/accountabilities ØDiscuss with workers to obtain information ØStart identifying factors and concerns Heating & Cooling Service Experts Define Tools Ø Project Charter Ø FlowChart/Task Mapping Ø Stakeholder Analysis Ø Benchmarking Analysis Refrigeration Heating & Cooling Service Experts Refrigeration DMAIC Stage Ø Measure current ergonomic program Ø Initial data gathered Ø Categorize initial data Ø Perform an analysis to identify high impact areas Ø Develop performance metrics & project scorecard Ø Perform ergonomic evaluations of work tasks and work environment Heating & Cooling Service Experts Refrigeration Measure Tools Ø Critical to Quality (CTQ) Ø Histograms Ø Pareto Charts Ø Assessments (Office, Lifting, Hands & Arms) Ø Checklist Heating & Cooling Service Experts DMAIC Stage Ø Initial problem analysis Ø Develop cause and effect relationships Ø Determine and validate root causes Ø Investigate and quantify job requirements Ø Analysis of human performance and physiological response Refrigeration Heating & Cooling Service Experts Refrigeration Analyze Tools Ø Cause and Effect Analysis (Ishikawa diagram) Ø Failure Mode & Effect Analysis (FMEA) Ø Design of Experiments (DOE) Ø Prioritization Matrix Heating & Cooling Service Experts Refrigeration DMAIC Stage Ø Identify breakthroughs and select practical approaches Ø Gain approval to implement improvements Ø Design or redesign strategies Ø Implement ergonomic intervention Ø Establish medical control policies Ø Train management, supervision, and workers in correct methods and sources of problems Heating & Cooling Service Experts Refrigeration Improve Tools Ø Ergonomic Training Video Tapes Ø Assessments (Office, Lifting, Hand & Arms) Ø Checklist Ø Cost-Benefit Analysis Ø Responsibility Matrix Ø Quality Function Deployment Heating & Cooling Service Experts Refrigeration DMAIC Stage Ø Measure results, develop control methods and manage change Ø Report scorecard data & create a process control plan Ø Continually improve the process P-D-C-A cycle is repeated (Kaizen events) Ø Focus on engineering and administrative controls Ø Educate employees through training Heating & Cooling Service Experts Control Tools Ø Balanced Scorecard Ø Checklist Ø Assessments Ø Histograms Ø Pareto Charts Refrigeration Heating & Cooling Service Experts Refrigeration Conclusion Ø Systemic approach Ø Ergo-Sigma framework Ø Continuous improvement Ø Quantitative tools to identify ergonomics root causes Ø Control, improve, and predict risk factors