Lean 6-Sigma Program Department of Toxic Substances Control (DTSC) Inspection Report Project Shawn Cox Adam Palmer Keith Kihara ( Project Greenbelt) (Project Champion) (Executive Sponsor)
Enforcement and Emergency Response Division (EERD) We perform inspections and enforcement on the following: Universal Waste Facilities (E-Waste) Hazardous Waste Transporters Generators Treatment, Storage, and Disposal Facilities Lean 6-Sigma Program
Inspection Report Lean Six Sigma Problem Statement: From 2014-2016 DTSC completed about 84% of inspections within 65 days, as required by statute. Objective: Complete and submit 95% of inspection reports within 30 days. Primary Metric: Days from the first day of the inspection until submission to the operator. Project Team: Over 100 years of experience. Van-Anh Le Christie Bautista Josilynn Spray Abdalin Asinas Leah White Bailey Franklin Danny Demarco Ellen Pates Lean 6-Sigma Program
Analysis Tools Baseline Capability Analysis Capability Six Pack Interval Plot FMEA Scatterplot One-Way ANOVA Fishbone Diagram High Level Process Map Mood’s Median Test 2-Sample T Test Regression Analysis Lean 6-Sigma Program
Initial Process Map insert process map = Legally Required = Value Added = Data Collection = Non Value Added Most Non Value Added steps are in the review phase Lean 6-Sigma Program
Baseline Capability Process Capability Report for All inspections Calculations Based on Weibull Distribution Model UB Inspection Reports Completed insert capability analysis graph 0 40 80 1 20 1 60 200 240 Days to Completion of Inspection Report 35 day Inspection Report average 49% completed in 30 days Lean 6-Sigma Program
Baseline Capability without E-waste 30 Day Goal Calculations Based on Weibull Distribution Model 30 Day Goal UB Inspection Reports Completed insert capability analysis graph 0 40 80 1 20 1 60 200 240 Days to Completion of Inspection Report 56 day Inspection Report average 21% of Inspection Reports completed in 30 days Lean 6-Sigma Program
Difference Between E-waste and Other Facilities Days to Completion of Inspection Report insert graphical or analysis result How E-Waste is different Not all facilities should use a checklist Lean 6-Sigma Program
Timeframe for Class of Violations Class 1 Class 2 Minor No Violations Significant Difference Lean 6-Sigma Program
Number of Violations Regression Analysis Days to Completion of Inspection Report Number of Violations No Significant Relationship Lean 6-Sigma Program
Comparing Violations Found Violation Comparison By Percentage 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Total Inspections Total Violations Total Class 1's E-waste All Other Significantly fewer Class 1 violations from E-Waste Lean 6-Sigma Program
Critical X’s (root causes of problems) Inspection Report Template – No real template Consultation and Research – It is impossible to know all of the California Code of Regulations/Health and Safety Code Sampling – Not prepared to sample during the inspection Cyclical review phases Lean 6-Sigma Program
New Process Map 52 Steps initially 28 Steps after = Value Added = Legally Required = Data Collection = Non Value Added Lean 6-Sigma Program
Improvement Techniques Checklist for transporter inspections Class 2 Violation threshold for checklist based inspections (currently a Class 1 threshold) New inspection report template Sampling kit Health and Safety Code / California Code of Regulations database Penalty Determination Team in the instance of Class 1 Violations Standardized Cover Letter Eliminate Branch Chief review of Inspection Reports Lean 6-Sigma Program
Control Plan Monitor days to completion of Inspection Report by violations and facility type Ensure Report quality through audits Supervisors ensure staff have adequate sampling kits Ensure consistent usage of proper templates Lean 6-Sigma Program
Before and After – New Process Projected I Chart of Time to Completion by Before Before After 250 1 1 1 200 1 Individual Value 1 1 1 1 50 1 00 UCL=51.6 50 _ X=13.8 19.5 0 LB=0 1/7/2016 2/9/2016 3/22/201 6 4/27/2016 5/26/2016 6/29/201 6 9/1 3/2016 10/24/2016 1 2/6/2016 8/22/2017 9/26/201 7 INSPECTION DATE Worksheet: Worksheet 1; 7/20/2017; Created by Shawn Cox Inspection Report completion time shifts from 35 to 20 days Lean 6-Sigma Program
Additional Benefits Staff Morale Department Image Staff Efficiency Concise presentation of information Customer Satisfaction Compatible with future technology upgrades Lean 6-Sigma Program
A3 Performance Tracker Solution Implementation Tracking: General Information: item status Project Title : Inspection Report Lean Six Sigma New Inspection Report Pilot Agency/Department : Department of Toxic Substances Control Use Transporter Checklist Proposed Division/District/Office : Headquarters Champion/Process Owner : Adam Palmer CCR/HSC Database Proposed Green Belt : Shawn Cox Sampling Kits Proposed Executive Sponsor : Keith Kihara Class Two Violation Threshold Proposed Date : 7/17/2017 Penalty Determination Team Proposed Standard Cover Letter Proposed Problem Statement: Eliminate Branch Chief Review Proposed From 2014-2016 DTSC completed about 84% of inspection reports within 65 days, as required by statute. Updated Control Chart: I Chart of Chronological 1 250 1 1 200 1 Primary Metric: 1 1 1 150 UCL=135.8 Days to completion of Inspection Report Individual Value 100 Goal: Submit 95% of inspection reports within 30 days while maintaining or _ 50 X=35.6 increasing the quality of inspection reports. 0 Root Causes (Critical X’s): -50 Sampling - Not prepared to sample • LCL=-64.5 Consultation/Research - CCR/HSC • -100 Inspection Report Template - No Inspection Report Template • 1 30 59 88 117 146 175 204 233 262 Observation Cyclical Review Processes • Worksheet: Worksheet 1; 7/21/2017; Created by Shawn Cox Baseline Average : 35 Days Current Average : 35 Days Current Capability: 84% in 65 Days A3 Performance Tracker 20
Green Belt Contact Information Name: Shawn Cox Phone: (916) 322-7527 Email: shawn.cox@dtsc.ca.gov Lean 6-Sigma Program
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