How to Control an Ergonomics Program through Six-Sigma Methodology Ana M. Ferreras

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How to Control an Ergonomics
Program
through Six-Sigma Methodology
Ana M. Ferreras
Keith White, Ph.D., CPE, CEM
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Agenda
Ø Background
Ø Ergo-Sigma Model
Ø DMAIC Process
Ø Steps
Ø Tools
Ø Conclusion
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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
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Ergo-Sigma Structure
Management Vision
Strategic Planning
Six-Sigma
DMAIC
Daily Control
PDCA/Kaizen Teams
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DMAIC—Five Step Process
Define
Control
Improve
Measure
Analyze
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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
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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
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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
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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
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Define Tools
Ø Project Charter
Ø FlowChart/Task Mapping
Ø Stakeholder Analysis
Ø Benchmarking Analysis
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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
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Measure Tools
Ø Critical to Quality (CTQ)
Ø Histograms
Ø Pareto Charts
Ø Assessments (Office, Lifting, Hands & Arms)
Ø Checklist
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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
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Analyze Tools
Ø Cause and Effect Analysis (Ishikawa diagram)
Ø Failure Mode & Effect Analysis (FMEA)
Ø Design of Experiments (DOE)
Ø Prioritization Matrix
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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
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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
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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
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Control Tools
Ø Balanced Scorecard
Ø Checklist
Ø Assessments
Ø Histograms
Ø Pareto Charts
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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