Emerging Trends in Security
“How to use Lean Six Sigma
approach in Security
Optimization”.
Success Story
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
Presented by:
Lili-Ann Mitchell, CPP
© 2008, ALCAN Inc.
The past months…
July 2007 - Rio Tinto Offer
October 2007 - Offer accepted by
Alcan
February 2008 - Rio Tinto
Integration
May 2008 - Rio Tinto Global
Security Integration
The project presented was
completed prior to the integration
and reflects the Alcan context
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 2
© 2008 ALCAN
Content
Global Security Project
CI at Alcan
The Success Story (DMAIC Process)
Define Phase
Measure Phase
Analysis Phase
Improve Phase
Control Phase
Conclusion
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 3
© 2008 ALCAN
Global Security
Project
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Alcan Global Security Project
(Pechiney Integration)
Lean Six Sigma
Security Survey
2004
Security Guard
Global Contract
2005
CI Project
2006 (Pilot)
2007 (Roll-out)
Security Optimization
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 5
© 2008 ALCAN
CI at Alcan
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
CI: To better execute
Alcan’s business strategy
“Continuous Improvement will enable us to better
execute our business strategy. This is one of the biggest
investments in our people that we ever made.
Offering a common toolbox to meet your individual and
team objectives, it will empower you as you will benefit
from training techniques, sharing of best practices and
knowledge transfer” .
Travis Engen, CEO, 2003
CI Strategy 2010:
Green Belt and Black Belt at Senior Level
Total 0,7% of BB : approximately 420 people trained
Total 2-3% of GB: approximately 1800 people trained
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 7
© 2008 ALCAN
Alcan CI is the integration
of two approaches
Gate Review
Gate Review
Gate Review
Gate Review
DMAIC
Lean
Speed+Low Cost
Success Story
Six Sigma
Customer+Quality
Goal – Reduce waste and
increase process speed
Goal – Improve performance on
critical criteria for customers
Focus – Identify non-valueadded steps and causes
of delay
Focus – Use DMAIC
with other tools to
eliminate variation
Bias – Quick wins
and Kaizen events
Method – Broader management
engagement, 1% dedicated
as Champions and Black Belts
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 8
© 2008 ALCAN
CI essential steps
Success Story
Project selection (Project Charter)
Team selection
Team launch
Sponsor = Stakeholder
Gate reviews every phase to obtain the GO!
CI Tool Box
FOCUS, FOCUS, FOCUS… stick to the process!
Celebrate success!!
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 9
© 2008 ALCAN
The
Success Story
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Opportunity (Project Charter)
Alcan spends over 7.5 million US$/yearly (2003 survey
results) for External Security Guard Services, in more
than 70 facilities in 23 countries.
With an earlier CI project we reduced cost of security
services by 40% with an annual savings of 132K while
improving the service level.
Roll-out this methodology to other Alcan facilities with
external security guards in order to optimize security
services across the company.
Mandate: Upgrade effectiveness of the external
security services while reducing aggregate Alcan
monthly cost of external security services by 20%.
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 11
© 2008 ALCAN
Results
51%
of Alcan sites (35) increased efficiency
957K
USD Recurrent Savings
22,8%
Value
of total cost reduction
Creation of more than 6.5M USD
Investment
Success Story
(CAPEX) of 1,1 M.
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 12
© 2008 ALCAN
Define Phase
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
SIPOC (Y = f (X)
Supplier
Alcan
sites
with external
security guards
Corporate
Security
Input (X)
Process
Output (Y)
Requirements
Delivery
for security
security
services by
external
security
guards
Security
Existing
security
measures
risks
of
Customer
Aggregate
Plant
costs of
external
security guard
services
managers
Alcan
personnel,
visitors and
contractors
Effectiveness
of external
security guard
services
Corporate
Security
Metrics
Input (impact on Y)
Process
x = # of sites with external security guards (to be validated in define phase)
x = Opportunity for improvement
x = Cost of security recommendations
x = # of sites using Procurement Master Service Agreement for Security
Guards
x = Number of Guards
x = Average hourly rate
x = Average of hours worked by external security guards
x = Security equipment used
x = Security risks (Business Profile)
x = Security requirements (based on Alcan Security Program)
x = Security level (GAP between recommended and current level)
x = Security Incidents
X= Security
guards
background check
Success Story
X = Hours of
security guards
training
X = Qualifications
(1st aid, fire, etc.)
X = Security
guards number of
years of
experience
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 14
Output
Y1 = Aggregate
Alcan monthly
cost of security
services at sites
with external
security guards.
Y2 = Effectiveness
of security
services at Alcan
sites with external
security guards.
© 2008 ALCAN
Voice of Customers
Improvements required in terms of security services
(response rate: 77% of the sites in the project) :
Personnel
25,8% (More training for security guards,
Reduce turnover)
Security
Management 37,6% (improve candidate selection,
increase supervision, implement/increase daily checks,
reduce number of guards/hours, overall satisfied with the
service level)
Security
equipment 36,6% (increase/improve use of
technology (CCTV, alarm system, access control,
communication, parking security, etc.)
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 15
© 2008 ALCAN
Measure Phase
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Data Collection Plan
A generic example...
Performance
Measure
Operational
Definition
Data Source
and Location
How Will
Data Be
Collected
Who Will
Collect Data
Developed
earlier in
SIPOC
2
3
4
5
When Will
Data Be
Collected
How will data be used?
How will data be displayed?
Examples:
Identification of Largest Contributors
Identifying if Data is Normally Distributed
Identifying Sigma Level and Variation
Root Cause Analysis
Correlation Analysis
Examples:
Pareto Chart
Histogram
Control Chart
Scatter Diagrams
Sample Size
6
Stratification
Factors
1
Let’s see how a data collection plan is developed…
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 17
© 2008 ALCAN
Stratification Factors
1
2
3
4
Questions About Process
Stratification factors
X Variables
Measurements
Is security at Alcan sites
efficient?
Delivery of
Security services
# of guards used by day
Period of the day
# of minutes per day
Security
Services at
Alcan Facilities
Does data exist to
support these
measurements?
(Y/N)
5
What task
With security equipment
Will these
measurements
By people other
help to predict Y?
than security personnel
(Y/N)
(Output)
How much does it
cost?
1
Monthly cost by
site
Hourly rate paid
6
# hours per day
2
Critical Xs = What Xs have the biggest impact on my quality (Y1) and
my cost (Y2)
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 18
© 2008 ALCAN
Data Collection Plan
Data Collection Plan
Performance Measure
Operational Definition
Data Source
How will the
data be
collected
By whom
# of guards used by day
# guards per 24h
Sites
Data sheet
Security Managers Measure Phase 35 sites Delivery of security services
Period of the day
day, evening, night, w-e orSites
holiday
Data sheet
Security Managers Measure Phase 35 sites Delivery of security services
# minutes per day
# minutes of security per 24h
Sites
Data sheet
Security Managers Measure Phase 35 sites Delivery of security services
What Task
duties of security guards Sites
Data Sheet
Security Managers Measure Phase 35 sites Delivery of security services
is security equiment use list of security equipment Sites
Data sheet
Security Managers Measure Phase 35 sites Delivery of security services
By other people other thannot
security
security
personnel
personnel
Sites
Data sheet
Security Managers Measure Phase 35 sites Delivery of security services
Hourly rate paid
USD hourly rate
Sites
E-mail
Security Managers Define Phase
90 sites Cost of security services
# hours per day
# of hours per 24h
Sites
E-mail
Security Managers Define Phase
90 sites Cost of security services
2
Success Story
3
4
When
5
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 19
sample
size
stratification factor
6
© 2008 ALCAN
Who Will Collect the Data?
Be sure they...
Give input during the check sheet design / validation
Understand operational definitions
Understand how data will be tabulated
Helps them see the consequences of changing
Have any necessary process knowledge
Have adequate training and practice
Will remain unbiased
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 20
© 2008 ALCAN
Data Collection Sheet (1/2)
External Security Guard Services Evaluation
General Information
Date:
Alcan Site:
Alcan resource managing this contract:
External Security Guard Supplier:
Supplier contact name, position and phone number:
Monthly cost (US$):
Contract end date:
Master Service Agreement Implemented
Security Manager Completing the Evaluation
Plan of the site/Pictures obtained
Business Security Profile
Security Costs
Evening (16h Personnel
Number of External Security Guards
Number of Alcan personnel performing security duties
Day (8h - 16h)
12h)
Night (12h - 8h) Week-end
Security chief
Shift Supervisor Guard
Used Yes/No
Annual
Investment
Annual
Maintenance fee Planned
Patrol Guard
Holiday
Alcan Personnel
(performing
security duties)
Other
Hourly rate in USD$
Equipment
Access Control
Security Alarm System
Fire Alarm System
CCTV
Recording device
Security Communication (walkie-talike, cell phone, etc.)
Perimeter Protection
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 21
© 2008 ALCAN
Data Collection Sheet (2/2)
Security Duties
What
Who
When
Select from Menu
Select from Menu
Select from Menu
Security Data
Evening (16h 12h)
Day (8h - 16h)
Security
# of hours by manager
task
Evaluation
Notes on
Potential
improvements
Select from Menu
Night (12h 8h)
Week-end
Holiday
Access control
# of employees accessing site
# of visitors/contractors accessing site
average time for visitors/contractors registration (in minutes)
# of vehicles
Patrol and Security Inspections
# of security patrols
# of security check points in patrol and/or security inspections
Alarm System Response and Monitoring
# of alarm
average Response time for on-site external security guards
average Response time from outside patrol
Comments
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 22
© 2008 ALCAN
Analysis Phase
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Analysis – Critical Xs
Surveillance standby is the security task requiring the
most time (44%) and is not a value add task
Week-end shift efficiency is very low (14%)
Evening/night shift efficiency at 50%
Other non security duties should be reviewed (14% of
the time)
No CCTV monitoring
Access Control (Visitors, employees, contractors)
Alarm System Response and Monitoring
CCTV Monitoring
Patrol and Security Inspections
Surveillance/standbye
Emergency Intervention (Security, Fire, Medical)
Supervision, Replacement (lunch, breaks)
Communication, Reporting (Daily and special events reports)
Other security duties
Other non security duties
Total hours of security duties
Total available hours
% security hours vs available hours
Total hours of security duties (without standbye time)
% security hours vs available hours (without standbye time)
Success Story
Security Duties
guard
evening/nigh
guard w-e (48h)
holiday
guard day (6h- t (18h-6h) 2 Total per day
(24h)
18h) 2 FTEs
FTEs
2 FTEs
Total w-e (48h)
# of hours
5,5
0,5
0,5
0,5
5
2,5
0
1,5
1
0
0
8
12
8
12
18
38
16
38
2
1
2
1
1
1
2
1
8
20
24
83%
18
75%
1
28
24
117%
12
50%
3
1
8
48
48
100%
30
63%
51,5
96
54%
13,5
14%
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 24
0
0
0
51,5
96
54%
Pareto
analysis
80/20
% of
Total hours per hours per
week
week
28
12,5
0
52
128
11
0
15
5
40
291,5
336
87%
163,5
49%
10%
4%
0%
18%
44%
4%
0%
5%
2%
14%
76%
© 2008 ALCAN
Critical X Analysis
Analysis
Improve
Critical X
Potential Solutions
Security Level
Security Evaluation
Hourly rate
renegotiate contract with Graber,
no procurement effort was done
yet for a volume negotiation
(phase 1)
Number of guards
Reduce guards (2)
Install CCTV with infra-red
perimeter detection system and
other devices
Monthly fire extinguisher
inspection
Low Efficiency of the security
services (security incidents)
Standbye time (42%)
Service level of supplier is
mediocre
Access Control
Lighting around perimeter is not
sufficient
Success Story
Example
Improve
Control
Actions Plan
Quality Impact
Implement SAV
Recommendations
Increase Security Level
choose companies to 2nd
phase, facilities visit,
proposals, choose
supplier, negotiate
cotract,
Day shift (L-V 4 guards),
Night Shift (L-V, w-e, hol.
3 guards)
Install CCTV(12) with
infra-red perimeter
detection system and
other devices, ensure
lighting is adquate for
CCTV needs.
Cancel monthly external contract
assign task internally to foot patrol
guard or fire brigade personnel.
Maintain annual inspection by
external company.
Change Security Company,
Change Contract manager
(external), implement security
Implement SAV
policies and directives.
recommendations
Reduce guards, reassign security
tasks
New supplier
Master service agreement
Improve service
Implement automated gates for
access control outside rush period Implement SAV
(after and before shifts)
recommendations
CCTV surveillance of access
Implement SAV
increase lighting
recommendations
Control
Potential Savings
Control
Investment
required
Who
When
121K
XYZ
Oct
XYZ
Q2 2007
XYZ
Q4 2007
XYZ
Oct
90k
Improve
Improve
Better knowledge of fire
extinguisher localisation
by security personnel
and/or fire brigade.
Q4 2007
Security of the site
improvement and followup.
Q4
Q4
Q4
Q4
Q4
Better use of standbye
time, more security for
parking lot.
Reduce personnel
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 25
TBD
XYZ
XYZ
Oct
Oct
XYZ
Oct
© 2008 ALCAN
Improve Phase
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Improvements
For the 35 sites in the project:
51%
increased their efficiency
43%
renegotiated their security guard contract
34%
reduced the number of hours for security guards
29%
implemented new CCTV equipment
22,8%
cost reduction from total cost
Status
quo maintained for 29% of the sites.
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 27
© 2008 ALCAN
Control Phase
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Control Plan
Is delivered to transfer knowledge to the process owners
(summary of project)
Contains performance indicators to sustain the gains
(Quality/Costs)
Assists in highlighting opportunities for further improvement
activities
Is a living document
Is interesting and easy to understand – use pictures and colors
Is signed by the process owner
Is validated during the validate phase (6-12 months after the
control phase)
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 29
© 2008 ALCAN
Performance Indicators 1 of 2
Performance Indicators of Security Guard Services
Security Duties Performed
Access Control (Visitors, employees, contractors)
Alarm System Response and Monitoring
CCTV Monitoring
Patrol and Security Inspections
Surveillance/standbye
Emergency Intervention (Security, Fire, Medical)
Supervision, Replacement (lunch, breaks)
Communication, Reporting (Daily and special events reports)
Other security duties
Other non security duties
Total hours of security duties without standbye
Total available hours
% security hours vs available hours
Security Equipment
Access Control
Security Alarm System
Fire Alarm System
CCTV (Videosurveillance)
Recording device (enregistrement)
Security Communication (walkie-talkie, cell phone, etc.)
Perimeter Protection
Time spent per week (7
days)
Comments/ Diagram
Before
After
28
28
12,5
12,5
0
30
validate after
52
52
128
56
less standbye time
11
11
0
0
15
15
5
5
40
40
163,5
193,5
336
228
security guard reduce to one only on night and w-e
49%
85%
Used Yes/No
Before
After
yes
yes
partial
no
no
complete
yes
yes
partial
complete
Security Cost (Personnel)
Before
improvement of the fire detection system
$ USD
After
Number hours per month
Hourly rate ($US)
Monthly Cost ($ US)
25K euros
Security Cost (Equipment)
Before
Maintenance fee per month ($ US)
Investment (CAPEX) fee per month ($ US)
Success Story
12,5 K
euros
savings of 150K Euros, starting in Q3 2008
$ USD
After
300 K Euros Q1 2008
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 30
© 2008 ALCAN
Performance Indicators
Security Data (Quality)
Before
$ USD
After
Access Control
Efficiency of access control (visitors, employees, vehicles) %
Time to register one visitor (in minutes)
Time dedicated for EHS training at reception (in minutes)
Time to control one vehicle (in minutes)
anti-pass back
Patrol/Security Inspections
# of patrol/security inspections
# of checkpoints per patrol/security inspection (extérieur)
# of checkpoints per patrol/security inspection (intérieur)
Alarm system Response and Monitoring
Intrusion Detection Alarm
# of alarms
average Response time for on-site external security guards (in minutes)
3 min.
average Response time from outside patrol (in minutes)
non
2
7
13
2
7
13
30 sec.
5 min.
caméras validation de l'alarme
Centr'Alp
Technical Alarm (ESS)
# of alarms
average Response time for on-site external security guards (in minutes)
3 min.
average Response time from outside patrol (in minutes)
non
8 min.
5 min
voir possibilité mettre caméras????? Four, salle informatique
Centr'Alp
four (risque critique)
average Response time for on-site external security guards (in minutes)
3 min.
average Response time from outside patrol (in minutes)
non
30 sec.
5 min.
mettre une caméra
Centr'Alp
gaz (risque moyen)
average Response time for on-site external security guards (in minutes)
3 min.
average Response time from outside patrol (in minutes)
non
8 min.
5 min.
ok comme performance (à valider avec ESS)
Centr'Alp
Fire Detection Alarm
# of alarms
average Response time for on-site external security guards (in minutes)
3 min.
average Response time from outside patrol (in minutes)
non
30 sec./ 8min.
avec caméras 30 sec. Si non 8 min. (cibler les endroits à risques)
5 min
Centr'Alp
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 31
© 2008 ALCAN
Sites Status Dashboard
EMEA SITES
Status
Excluded/ Withdraw
Measure/ 2008
Analyse
Implementation
Control
Validate
Success Story
1
4 x
3
2
10
1
1
21
2
3
4
5
6
7
8
AMERICAS
9 10 11 12 13 14 15 16 17 18 19 20 21
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
ASIA-PACIFIC
22 23 24 25 26 27 28 29 30 31 32 33
3
0
0
0
10
x
x
x
x
x
x
x
x
x
34
35
x
x
x
x
x
2
x
12
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 32
2
© 2008 ALCAN
Conclusion
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Define
Develop Charter and Frame Project
Y = f (x)
X
XX
X
X
X X X XX
X
X X XX
KPIV’s 10 - 15
X X X
X
X
X
X
X
X
Process Map
Cause and Effects Matrix
Basic Statistical Analysis
FMEA
X
Measure
Analyze
FMEA
Advanced Statistical Analysis
Improve
X X
S
Brainstorming
Show Stoppers
Business Culture
Force Field
Pairwise
Critical X’s 1 - 3
S S S S S
S S S S S
S S S S
S S S
S S S S
S
S SS
Solution Matrix
S
Best Solution
Implement
Control
Success Story
Sustain the Gain
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 34
© 2008 ALCAN
Security Optimisation Strategy
Global Security Survey
Project Charter (opportunity, scope)
Pilot project with DMAIC (1 sites - 12 months)
Roll-out of the strategy (35 sites - 24 months)
Security process (SIPOC)
DMAIC phases using CI tools
Results:
51% of sites increased efficiency
957K USD savings
22,8% of total costs reduction
Patience! Focus!
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 35
© 2008 ALCAN
Questions?
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Back-up slides
ASIS INTERNATIONAL - EUROPEAN
CONFERENCE
Barcelona April 13-16, 2008
© 2008, ALCAN Inc.
Potential Solutions 1/2
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 38
© 2008 ALCAN
Potential Solutions 2/2
Success Story
ASIS INTERNATIONAL, Barcelona, April 13-16, slide 39
© 2008 ALCAN