Improving the Laboratory
Using data and evidence to solve a problem is at the heart of the scientific method and is something laboratory professionals will do every working day. But how many of us have tried applying the same methods to the way their work is done in order to make it more efficient, less wasteful and more effective?
Many of our clients have successfully used Lean Six Sigma to improve the quality, speed and cost of their lab services, in fields as diverse as hospitals, pharmaceutical R&D, oil and gas exploration, environmental services and quality control. Improvements they successfully implemented include:
- Slashing rework rates and delighting customers by gaining a clearer understanding of client needs before work begins.
- Cutting sample turnround time up to 75% by changing layout to improve flow, eliminating bottlenecks and prioritising incoming work visually.
- Reducing consumable spend 30-50% by changing how and when items are replenished.
Many of the biggest benefits they tell us about, however, come from challenging the assumptions that have become ingrained in their workflows over time. One client found six different inspection and validation steps were performed after testing was complete before a report was sent to their customers: not only did each of these steps delay delivery of the urgently-awaited result, later inspections failed to capture mistakes which the first had failed to spot. Upon investigation, they found the successive inspections had been implemented in the belief they were a regulatory requirement, but in fact no such requirement existed. These inspections were inefficient, ineffective and unnecessary.
Lean Six Sigma delivers a structured approach to problem solving which uses observation and evidence to verify root causes, and disciplined project management to embed solutions so the problem goes away for ever. It was used in these projects to deliver huge and sustainable benefits to the laboratories concerned. If you haven’t already tried this way to improve the day-to-day operation of your labs, please contact us to make a start today!
Have you already applied continuous improvement methods to improve how your labs operate? If you did, would you do it again? If not, why not?
Disclaimer: The views expressed in this post are solely those of the author and do not necessarily reflect those of 100% Effective Ltd.
I've done many OE activities in QC labs, from 5S through SPC to human error reduction with hoshin and standard work thrown in for good measure. I'd do it all again. Critical things to understand, like you mentioned there, are any regulatory guidelines (I too have seen multiple checks thrown in as a response to single deviations because it was the 'right thing to do'), company policies, and understanding how the lab fits into the value stream. Often they're the last step before product release so responsiveness has to be built in to whatever OE initiatives you plan. Otherwise you're at risk of extending lead time or at the least building in redundancy.