Problem statement
Open scalpel-type blades were in use widely in operations areas. They were used for daily routine tasks such as opening boxes, cutting wire and slicing PU panels. Flimsy plastic scalpel handles were likely to snap and blades spring loose. This posed a health and safety (H&S) risk for employees on a daily basis. Prior to engaging with Lean Ireland, cuts had been reported, typically arising from the careless placement of blades on work surfaces.
Objective
Eliminate the use of open blades in operations, by providing an acceptable, safer and better alternative. Implement H&S guidelines & train all relevant operations staff.
Lean Ireland consulting/training work
The project was completed by a cross functional team of client employees, who undertook two-day Certified Lean Six Sigma Yellow Belt Training with Lean Ireland. The training provided the DMAIC (define, measure, analyse, improve and control) project framework for the team, plus a varied toolset to enable the team to work through the project phases. The Lean Ireland facilitator provided project mentoring on a regular basis throughout the project lifecycle.
The certified lean six sigma yellow belt (CLSSYB) training course is facilitated by Lean Ireland to ISO 13053-1 standards. Projects are completed by CLSSYB candidate teams. In this case the total consultant involvement was 10 days, including training and mentoring 3 separate YB project teams on site and online, certification evaluation, and award.
The yellow belt team used the lean six sigma DMAIC process and toolset. In the Define and Measure stages of the project, they surveyed users of the scalpels and conducted a gemba walk to identify all locations where scalpels were in use. In total 28 different locations were identified. In the analyse phase the team researched and purchased a range of potential alternative retractable blade knives.
Detailed results of the client work
In the Improve project phase, three models of safe retractable blade knives were selected and trialled with personnel on the shop floor, over a period of three weeks . One model in particular found favour and was purchased by supervisors. In addition sharps buckets were placed at each location where knives were used. Tweezers and snips were introduced for jobs involved in wire placement and wire cutting, where heretofore the scalpels had been used.
The training department conducted training on safe use of the knife and disposal of blades in the new sharps buckets. The retractable blade knives were distributed in all the relevant areas and scalpels removed.
In the Control project phase, a follow-up audit on retractable blade knife use was carried out by the team, plus interviews with operations staff. Overall the implementation was a great success, with staff in the quality lab also taking up use of the same brand of knife, rather than the scalpels.
Conclusion. Once people realise that there’s a danger, they are, willing to adopt a safer alternative if (a) they are consulted on options, (b) it’s a better option that the current tool or method, and (c) it is provided by the organisation.