System Performance Laboratory Optimization

Abstract

This project seeks to optimize the efficiency of a medical device laboratory process applying tools of the Lean Six Sigma methodology and eliminating non-value activities to complete transfer of a new product avoiding convert the current process in a bottleneck. The main objective is increasing the efficiency and throughput rate from 1.7 to 2.2 lots per shift while focusing on reducing the variability in the lots lead time. The Lean Six Sigma strategy involves the use of statistical tools within a structured methodology for gaining the knowledge needed and achieve faster and less expensive quality improvements. The strategic goal is to continually improve processes that have a real impact on business metrics to become a world class company. In this case, the throughput rate was increased from 1.7 to 2.9 lots per shift due to increase technician’s efficiency by 29%, while reducing the number of resources and the variability in the lots lead time from 1.26 to 0.81. The total project saving was $31,687 between reducing headcount and scrap cost saving. Key Terms ⎯ Bottleneck, DMAIC, Lean Six Sigma, Quality Improvement, Statistical Variation.